Absorbent Articles Comprising Graphics

ABSTRACT

An absorbent article may comprise a first zone comprising graphics and a second zone comprising graphics, wherein the first and second zones have different elastic properties. Further, the absorbent article may comprise a first absorbent article component and a second absorbent article component having substantially different elastic properties, wherein the first absorbent article component comprises an elastomer. Additionally, the absorbent article may comprise a third absorbent article component overlapping the first and second absorbent article components, wherein the third absorbent article component comprises graphics on at least the portions which overlap the first and second absorbent article components.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.13/006,913 filed on Jan. 14, 2011, which is a continuation of Ser. No.11/999,229 filed on Dec. 4, 2007, which claims the benefit of U.S.Provisional Application Nos. 60/872,697, filed Dec. 4, 2006, and60/899,985, filed Feb. 6, 2007, the substances of which are incorporatedherein by reference.

FIELD OF THE INVENTION

The present invention relates to the field of absorbent articles, andmore particularly to the field of absorbent articles comprising graphicsand/or color fields.

BACKGROUND OF THE INVENTION

There is a desire to make disposable absorbent articles look more likeunderwear. There are several factors that can affect whether anabsorbent article is perceived as underwear-like. These factors include,but are not limited to, the noticeability of seams, the existence ofgraphics on a larger percentage of the viewable outer surfaces of theabsorbent article, and graphics flowing from or over two or moreabsorbent article components.

There are, however, many obstacles to designing and executing anabsorbent article that is underwear-like. One reason is that as newdisposable absorbent article technologies are developed, they areincorporated as components. For example, seams are created to addstretchable elastomeric side panels or ears to the chassis and front orback regions of the absorbent article. Further, because of the manner inwhich absorbent article components are incorporated, even the viewableouter surfaces of the article have seams. Thus, it is challenging toplace graphics on these individual components and to line them up suchthat the seams are not emphasized by process variations. Further,depending on the type of article construction, it is challenging tomaintain the desired levels of breathability when adding graphics toeach of the components having outer viewable surfaces. For these andother reasons, it is challenging to create an absorbent article thatcomprises mainstream technologies and also comprises graphics onmultiple absorbent article components, such that the graphics flow fromabsorbent article component to component in a manner that deemphasizesseams and creates a holistic underwear-like appearance.

It is a desire of the present invention to provide absorbent articlesthat look like underwear, while, at the same time, incorporatingabsorbent article components that offer the benefits and functionalityof the latest technologies (e.g., high stretch components integratedwith low/no stretch components, highly breathable components, etc.).More specifically, it is a desire of the present invention to provideabsorbent articles comprising graphics spanning the viewable absorbentarticle components, including absorbent articles comprising stretchableand breathable components. Further, it is a desire of the presentinvention to provide absorbent articles that have a Seam NoticeabilityRating of less than about 7,

BRIEF DESCRIPTION THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the invention, it is believed that the presentinvention will be better understood from the following description ofembodiments which are taken in conjunction with the accompanyingdrawings and which like designations are used to designate substantiallyidentical elements, and in which:

FIG. 1 is a perspective view of an embodiment of an absorbent article ofthe present invention;

FIG. 2 is a perspective view of an alternate embodiment of the absorbentarticle of FIG. 1, wherein the shape and orientation of the ear panelsare altered;

FIG. 3 is a partially cut-away plan view of the absorbent article ofFIG. 1;

FIG. 4 is a cross-sectional view of the absorbent article of FIG. 3taken along the section line 4-4;

FIG. 5 is an exploded perspective view of an elastic member of an earpanel of the absorbent article of FIG. 1;

FIG. 6 is a perspective view (in use) of the absorbent article of FIG. 1illustrating various zones;

FIGS. 7A and B are perspective views (in use) of the absorbent articleof FIG. 1 comprising alternate graphics;

FIG. 8 is a perspective view of the absorbent article of FIG. 1comprising alternate graphics;

FIG. 9 is a perspective view of the absorbent article of FIG. 1comprising alternate graphics;

FIGS. 10A-C are perspective views of the absorbent article of FIG. 1comprising alternate graphics;

FIG. 11 is a plan view of an embodiment of an absorbent article of thepresent invention;

FIG. 12 is a cross-sectional side view of a machine vision systemcomprising the absorbent article of FIG. 11;

FIG. 13 is a partial side view of the absorbent article of FIG. 11,wherein the ear panels are shown overlapping, wherein the ear panelscomprise alternate graphics;

FIGS. 14A-C are perspective views of the absorbent article of FIG. 1illustrating various color gradations;

FIG. 15A is a partial side view of the absorbent article of FIG. 11,wherein the ear panels are shown overlapping, wherein the ear panelscomprise alternate graphics;

FIGS. 15B-C are plan views of an ear panel of the absorbent article ofFIG. 11;

FIGS. 16A-B are partial side views of the absorbent article of FIG. 11,wherein the ear panels are shown overlapping, wherein the ear panelscomprise alternate graphics;

FIG. 17 is a partial side view of the absorbent article of FIG. 11,wherein the ear panels are shown overlapping, wherein the ear panelscomprise alternate graphics, and wherein a seam margin is illustrated;

FIG. 18 is a perspective view of an embodiment of an absorbent articleof the present invention;

FIG. 19 is a side view of an embodiment of an absorbent article of thepresent invention in use;

FIG. 20 is a side view of the absorbent article of FIG. 19 comprisingalternate graphics;

FIG. 21 is a top view representation of a standardized grading room foruse in the Method for Generating a Seam Noticeability Rating;

FIGS. 22A-D are side view representations of the four classes ofpatterns for use in the Method for Generating Seam Noticeability TestImages; and

FIGS. 23-26 are representations of images tested according to the Methodfor Generating a Seam Noticeability Rating.

DETAILED DESCRIPTION OF THE INVENTION

As used herein, “colored absorbent article component” refers to acomponent of an absorbent article which comprises color, but does notcomprise a graphic (as defined herein). Colored absorbent articlecomponents may comprise gradations of color.

As used herein, “elastomer” refers to any material exhibiting elasticproperties as described herein.

As used herein, “elastic” or “elastomeric” refers to any material whichis able to extend to a strain of at least 50% without breaking orrupturing when subjected to a tensile force, and is able to recoversubstantially to its original dimensions after the force has beenremoved; where % strain−((extended length−unextended length)/unextendedlength)×100.

As used herein, “extensible” refers to any material that generally isable to extend to a strain of at least 50% without breaking orrupturing.

As used herein, “graphic” refers to formation of an object, which may ormay not be colored. A graphic, however, does not include a field ofcolor alone, wherein no formation of an object exists.

As used herein, “graphic absorbent article component” refers to acomponent of an absorbent article which comprises a graphic. Graphicabsorbent article components may additionally comprise color, includingcolor accents, or a field of color which does not form part of anobject.

As used herein, “non-stretchable” refers to materials which cannotstretch to at least about 5% on the upcurve of the hysteresis test at aload of about 400 gm/cm. U.S. Prov. Pat. App. No. 60/811,580 describesthe hysteresis test in greater detail.

As used herein, “seam margin” refers to the distance between a distalpoint of a graphic on a first graphic absorbent article component and anoverlapping edge of a second graphic absorbent article component. Referto FIG. 13.

As used herein, “set” or “percent set” refer to the percent deformationof an elastomeric material measured while the material is in a relaxedcondition for a specified period of time after the material was releasedfrom a specified elongation without allowing the material to snap backcompletely. The percent set may be expressed as [(zero load extensionafter one cycle-initial sample gauge length of cycle 1)/(initial samplegauge length of cycle 1)]×100. Zero load extension refers to thedistance between the jaws at the beginning of the second cycle before aload is registered by the tensile testing equipment. Further definitionof “set” or “percent set” may be found in U.S. Pat. No. 6,617,016.

As used herein, “stretchable” refers to materials which can stretch toat least an elongated length of about 105% on the upcurve of thehysteresis test at a load of about 400 gm/cm. U.S. Prov. Pat. App. No.60/811,580 describes the hysteresis test in greater detail.

As used herein, “viewable inner surface” refers to the viewablebody-facing surface (e.g., topsheet 24. The viewable inner surface maycomprise multiple layers).

As used herein, “viewable outer surface” refers to the outer facingsurface of an absorbent article which is viewable when the absorbentarticle is worn (e.g., the garment facing side of the outer cover 22).The viewable outer surface may comprise multiple layers.

As used herein, “whole graphics” refers to a complete graphic,uninterrupted by absorbent article component finishing or one absorbentarticle component overlapping another. Refer to FIG. 15C whichillustrates whole graphics, whereas FIG. 15B illustrates graphics whichare interrupted or cut-off.

Reference will now be made in detail to embodiments and illustrations ofthe present invention(s). Except for FIGS. 21-22A-D, numerals with thesame last three digits represent the same or similar elements throughoutthe figures (e.g., 122, 1122, 2122, or 20, 1020, 2020).

Referring to FIG. 1, an absorbent article 20 of the present inventionmay have a front region 26; a back region 28 and a crotch region 30between the front region 26 and the back region 28. A chassis 41 may beprovided in the front, back and crotch regions 26, 28 and 30. Thechassis 41 may include a liquid pervious topsheet 24, a nonwoven outercover (interchangeably referred to as a “backsheet”) 22, a liquidimpervious film 68 (see FIG. 3) associated with the topsheet 24, and anabsorbent core 25 (see FIG. 3) disposed between the topsheet 24 and thefilm 68.

The absorbent article 20 may include a pair of extensible front earpanels 46, each extending laterally outward from the corresponding sidesof the chassis 41 in the front region 26, and a pair of extensible backear panels 48, each extending laterally outward from the correspondingsides of the chassis 41 in the back region 28 (“ear panels” and “sidepanels” may be used interchangeably). Each of the ear panels 46 and 48may have an outermost edge 240 which forms an outermost edge line 242.At least one of the outermost edge lines 242 may have a nonuniformlateral distance LD from the longitudinal center line 100 (see FIG. 3)in an uncontracted state. The absorbent article 20 may further includebonds 32, each joining the front and back ear panels 46 and 48 along thecorresponding edge lines 242 to form two leg openings 34 and a waistopening 36.

The pairs of the ear panels 46 and 48 may be elastically extensible inat least the lateral direction. In alternative embodiments, the earpanels 46 and 48 may be elastically extensible both in the lateral andlongitudinal directions.

The ear panels 46 and 48 may be formed by unitary elements of theabsorbent article 20 (wherein the ear panels 46 and 48 are notseparately manipulative elements secured to the absorbent article 20,but are formed from and are extensions of one or more of the variouslayers of the absorbent article). Each of the ear panels 46 and 48 maybe a projected member of the chassis 41 (more clearly shown in FIG. 3).The ear panels 46 and 48 may include at least one unitary element or acontinuous sheet material (e,g., the nonwoven outer cover 22 in FIG. 4)that forms a part of the chassis 41 and continuously extends into theear panels 46 and 48. Alternatively, the ear panels 46 and 48 may bediscrete members which do not have any unitary element that forms a partof the chassis 41, and may be formed by joining the discrete members tothe corresponding sides of the chassis 41 (see FIG. 11).

The absorbent article 20 may further include seam panels 66, eachextending laterally outward from each of the ear panels 46 and 48; andtear open tabs 31 each, extending laterally outward from the seam panel66. Each of the seam panels 66 may be an extension of the correspondingear panels 46 and 48, or at least one of the component elements usedtherein, or any other combination of the elements. Each of the tear opentabs 31 may also be an extension of the corresponding seam panel 66 orat least one of its component elements used therein, or any othercombination of its elements.

The tear open tab 31 can take any shape as long as it facilitatesintentional tearing open at the bonds 32 after soiling of the absorbentarticles 20. The lateral distance LD from the longitudinal center line100 may increase towards the leg opening 34 (not shown).

Corresponding edge portions of the chassis 41 and/or the ear panels 46and 48 may be bonded directly or indirectly (e,g., through the seampanels 66), in an overlapping manner to form a seam 258. As shown inFIG. 2, the front ear panel 46 may overlap the back ear panel 48.Alternatively, as shown in FIG. 2, the back ear panel 1048 may overlapthe front ear panel 1046. Alternatively, the front and ear panels 46 and48 can be bonded in a butted manner (not shown in Figs.). The bonding ofthe bonds 32 can be performed by any suitable means known in the artappropriate for the specific materials employed in the chassis 41 and/orthe ear panels 46 and 48. Thus, sonic sealing, heat sealing, pressurebonding, adhesive or cohesive bonding, sewing, autogeneous bonding, andthe like may be appropriate techniques. The seam panels 66 may be joinedby a predetermined pattern of heat/pressure or ultrasonic welds whichwithstands the forces and stresses generated on the absorbent article 20during wear.

A continuous belt 38 may be formed by the ear panels 46 and 48, and apart of the chassis 41 about the waist opening 36 as shown in FIGS. 1and 2. Elasticized waist bands 50 may be provided in both the frontregion 26 and the back region 28.

FIG. 3 is a partially cut-away plan view of the absorbent article 20 ofFIG. 1 in its uncontracted state (except in the ear panels 46 and 48which are left in their relaxed condition) with the topsheet 24 facingthe viewer, prior to the ear panels 46 and 48 being joined together bythe bonds 32. As illustrated, the absorbent article 20 may have thefront region 26, the back region 28 opposed to the front region 26, thecrotch region 30 positioned between the front region 26 and the backregion 28, and a periphery which is defined by the outer perimeter oredges of the absorbent article 20 in which the side edges are designated150 and 240, and the end edges or waist edges are designated 152. Thetopsheet 24 may be the body-facing surface of the absorbent article 20which may be positioned adjacent to the wearer's body during use. Thenonwoven outer cover 22 (also known as a backsheet) may have theouter-facing surface of the absorbent article 20 which may he positionedaway from the wearer's body. Additionally, the outer cover 22 maycomprise graphics 10 (described more below). The absorbent article 20may include the chassis 41 including the liquid pervious topsheet 24,the liquid impervious film 68 associated with the topsheet 24, anonwoven outer cover 22, and the absorbent core 25 positioned betweenthe topsheet 24 and the impervious film 68. In an alternate embodiment,there may be no impervious film 68, but rather, a nonwoven core forminglayer (not shown), also known as a dusting layer, may serve the functionof the liquid impermeable film 68. The absorbent article 20 may furtherinclude the front and back ear panels 46 and 48 extending laterallyoutward from the chassis 41, the elasticized leg cuffs 52, and theelasticized waistbands 50. The topsheet 24 and the nonwoven outer cover22 may have length and width dimensions generally larger than those ofthe absorbent core 25. The topsheet 24 and the nonwoven outer cover 22may extend beyond the edges of the absorbent core 25 to thereby form theside edges 150 and the waist edges 152 of the absorbent article 20.

The absorbent article 20 may also have two centerlines, a longitudinalcenterline 100 and a transverse centerline 110. Herein, “longitudinal”refers to a line, axis, or direction in the plane of the absorbentarticle 20 that is generally aligned with (e.g., approximately parallelwith) a vertical plane which bisects a standing wearer into left andright halves when the absorbent article 20 is worn. Herein, “transverse”and “lateral” are interchangeable and refer to a line, axis or directionwhich lies within the plane of the absorbent article that is generallyperpendicular to the longitudinal direction (which divides the wearerinto front and back body halves). The absorbent article 20 and componentmaterials thereof may also have a body-facing surface which faces theskin of wearer in use and an outer-facing surface which is the oppositesurface to the body-facing surface.

Each of the ear panels 46 and 48 of the present invention may have anoutermost edge line 242. Herein, “edge line” refers to lines whichdefine the outlines of the ear panels 46 and 48 or the chassis 41.Herein, “outermost” refers to portions which are farthest from thelongitudinal centerline 100. At least one of the edge lines 242 may havea nonuniform lateral distance LD from the longitudinal center line 100in the uncontracted state of the absorbent article 20.

The outermost edge line 242 may have a first point 251 at the closestportion to the waist opening 36 and a second point 252 at the closestportion to the leg opening 34, and the outermost edge line 242 is astraight line defined by connecting the first and second points 251 and252. The outermost edge line 242 shows the direction of the outermostedge 240 of the ear panel. The edge line 242 may lean to thelongitudinal center line 100 in the uncontracted state of the absorbentarticle 20. The outermost edge line 242 may have, in the uncontractedstate of the absorbent article 20, a lateral distance LD from thelongitudinal center line 100 which increases towards the leg opening 34as shown in FIG. 3. Alternatively, the outermost edge line 242 may have,in the uncontracted state of the absorbent article 20, a lateraldistance LD from the longitudinal center line 100 which decreasestowards the leg opening 34 (not shown in Figs,).

While the topsheet 24, the nonwoven outer cover 22, and the absorbentcore 25 may be assembled in a variety of well known configurations,exemplary chassis configurations are described generally in U.S. Pat.No. 3,860,003 (Buell); and U.S. Pat. No. 5,151,092 (Buell et al.).

FIG. 4 is a cross-sectional view of an embodiment taken along thesection line 4-4 of FIG. 3. The absorbent article 20 may include thechassis 41, including the liquid pervious topsheet 24, the nonwovenouter cover 22 associated with the topsheet 24, and the absorbent core25 positioned between the topsheet 24 and the nonwoven outer cover 22.The absorbent article 20 may further include the front ear panels 46,each extending laterally outward from the chassis 41, and inner barriercuffs 54. Although FIG. 4 depicts only the structure of the front earpanel 46 and the chassis 41 in the front region 26, a similar structuremay also be provided in the back region 28. Each of the front ear panels46 may be formed by a lamination of an extended part 72 of the barrierflap 56, an elastic member 70 and the nonwoven outer cover 22. Theelastic member 70 may include a plane elastomeric material 124 (see FIG.5). Herein, “plane elastomeric material” refers to elastomeric materialswhich continuously extend in two dimensional directions. Planeelastomeric materials include a scrim, a perforated (or aperturesformed) film, an elastomeric woven or nonwoven, and the like. The planeelastomeric material 124 may include at least a portion that has anonuniform lateral width.

The absorbent core 25 can be any absorbent member which is generallyconformable, non-irritating to the wearer's skin, and capable ofabsorbing and retaining liquids such as urine and other certain bodyexudates. The absorbent core 25 may be manufactured in a wide variety ofsizes and shapes (e.g., rectangular, hourglass, “T”-shaped, asymmetric,etc.) and from a wide variety of liquid-absorbent materials commonlyused in disposable absorbent articles and other absorbent articles suchas comminuted wood pulp which is generally referred to as airfelt.Examples of other suitable absorbent materials include creped cellulosewadding; meltblown polymers including coform; chemically stiffened,modified or cross-linked cellulosic fibers; tissue including tissuewraps and tissue laminates; absorbent foams; Absorbent sponges;superabsorbent polymers; absorbent gelling materials; or any equivalentmaterial or combinations of materials.

In an embodiment of the invention, the absorbent core 25 may have, inthe uncontracted state of the absorbent article 20, an area ratio of thecore area to the garment area of greater than about 25% or greater thanabout 40%. The core area is defined as the total area of the body-facingsurface of the absorbent core 25 in the uncontracted state of theabsorbent article 20. The periphery of the body-facing surface of theabsorbent core 25 is determined by the outline of aggregates of primaryabsorbent materials used in the absorbent core 25. Herein, “primaryabsorbent material” refers to absorbent materials which occupy more thanabout 80% in dry state volume of the absorbent core 25. Wood pulp (e.g.,airfelt) may be considered a primary absorbent material of the absorbentcore 25 and may define the periphery of the body-facing surface of theabsorbent core 25, thus defining the core area of the absorbent core 25.The other primary absorbent materials may include creped cellulosewadding; meltblown polymers including coform; chemically stiffened,modified or cross-linked cellulosic fibers; tissue including tissuewraps and tissue laminates; absorbent foams; absorbent sponges;superabsorbent polymers; absorbent gelling materials; or any equivalentmaterial or combinations of materials.

The garment area is defined as the total area of the body-facing surfaceof the absorbent article 20 in the uncontracted state. Therefore, thearea ratio is calculated as follows:

AR=CA/GA×100 wherein, AR: the area ratio (%), CA: the core area (cm²),GA: the total area (cm²)

The absorbent core 25 may have a core area of less than about 450 cm² orless than about 425 cm². The absorbent core 25 may have a maximum corewidth of less than about 12 cm or less than about 11 cm. Herein, “corewidth” refers to the lateral distance from one side edge to the otherside edge of the absorbent core 25.

The configuration and construction of the absorbent core 25 may vary(e.g., the absorbent core 25 may have varying caliper zones, ahydrophilic gradient, a superabsorbent gradient, or lower averagedensity and lower average basis weight acquisition zones; or may includeone or more layers or structures) Further, the size and absorbentcapacity of the absorbent core 25 may also be varied to accommodatewearers ranging from infants through adults. However, the totalabsorbent capacity of the absorbent core 25 should be compatible withthe design loading and the intended use of the absorbent article 20.

The absorbent article 20 may have an asymmetric, modifiedhourglass-shaped absorbent core 25 having ears in the front and backwaist regions 26 and 28. Other exemplary absorbent structures for use asthe absorbent core 25 that have achieved wide acceptance and commercialsuccess are described in U.S. Pat. Nos. 4,610,678, 4,673,402, 4,888,231,and 4,834,735.

The chassis 41 may further include an acquisition/distribution core 84of chemically stiffened fibers positioned over the absorbent core 25,thereby forming a dual core system. The fibers may be hydrophilicchemically stiffened cellulosic fibers. Herein, “chemically stiffenedfibers” means any fibers which have been stiffened by chemical means toincrease stiffness of the fibers under both dry and aqueous conditions.Such means include the addition of chemical stiffening agents which, forexample, coat and/or impregnate the fibers. Such means also include thestiffening of the fibers by altering the chemical structure of thefibers themselves, e.g., by cross-linking polymer chains.

The nonwoven outer cover 22 may include the liquid impervious film 68 asshown in, for example, FIG. 4. The liquid impervious film 68 maylongitudinally extend in the front, back and crotch regions 26, 28 and30. The liquid impervious film 68 may not laterally extend into at leastone of the ear panels 46 or 48. The liquid impervious film 68 may have abody-facing surface 79 and an outer-facing surface 77. The liquidimpervious film 68 may be impervious to liquids (e.g., urine) and may bemanufactured from a thin plastic film. However, the plastic film maypermit vapors to escape from the absorbent article 20. In oneembodiment, a microporous polyethylene film is used for the liquidimpervious film 68. A suitable microporous polyethylene film ismanufactured by Mitsui Matsu Chemicals, Inc., Nagoya, Japan and marketedin the trade as PG-P. A disposal tape (not shown in Figs.) mayadditionally be joined to the outer-facing surface of the nonwoven outercover 22 to provide a convenient disposal after soiling.

The nonwoven outer cover 22 may be compatible with other materials(e.g., component materials in the topsheet 24) used in the absorbentarticle 20, in terms of its design/process, for forming ventilationholes along the waist edge 152 and/or for forming bonds 32 in theabsorbent article 20.

In an alternative embodiment, the absorbent core 25 is not joined to thenonwoven outer cover 22, and/or the topsheet 24 in order to providegreater extensibility in the front region 26 and the back region 28.

The absorbent article 20 may further include an elasticized waistband 50that provides improved fit and containment. The elasticized waistband 50is that portion or zone of the absorbent article 20 which is intended toelastically expand and contract to dynamically fit the wearer's waist.The elasticized waistband 50 may extend longitudinally outwardly fromthe waist edge of the absorbent article 20 toward the waist edge of theabsorbent core 25. The absorbent article 20 may have two elasticizedwaistbands 50, one positioned in the back region 28 and one positionedin the front region 26, although other pull-on diaper embodiments can beconstructed with a single elasticized waistband. The elasticizedwaistband 50 may be constructed in a number of different configurationsincluding those described in U.S. Pat. Nos. 4,515,595 and 5,151,092.

The waistbands 50 may include materials that have been “prestrained” or“mechanically prestrained” (i.e., subjected to some degree of localizedpattern mechanical stretching to permanently elongate the material). Thematerials may be prestrained using deep embossing techniques as areknown in the art. Alternatively, the materials may be prestrained bydirecting the material through an incremental mechanical stretchingsystem as described in U.S. Pat. No. 5,330,458. The materials are thenallowed to return to their substantially untensioned condition, thusforming a zero strain stretch material that is extensible, at least upto the point of initial stretching. Examples of zero strain materialsare disclosed in U.S. Pat. Nos. 2,075,189, 4,107,364, 4,209,563,4,834,741 and 5,151,092.

At least one of the ear panels 46 and 48 may include the elastic member70 as shown in FIG. 4. The elastic member 70 of the front ear panels 46may include the elastomeric material 124 (see FIG. 5) which extendslaterally outward from the chassis 41 to provide good fit by generatingthe optimal retention (or sustained) force at the waist and side areasof the wearer. The elastomeric material 124 may be extensible in atleast one direction, including in the lateral direction, to generate aretention (or sustained) force that is optimal to prevent the absorbentarticle 20 from drooping, sagging, or sliding down from its position onthe torso without causing the red marking on the skin of the wearer. Inone embodiment, each of the ear panels 46 and 48 includes theelastomeric material 124.

The elastic member 70 may be operatively joined to at least one of thenonwoven webs 72 and 74 in the ear panels 46 and 46 to allow the elasticmember 70 to be elastically extensible in at least the lateraldirection. In one embodiment, the elastic member 70 is operativelyjoined to the nonwoven webs 72 and 74 by securing them to at least one,and in some cases, both of the nonwoven webs 72 and 74 while in asubstantially untensioned (zero strain) condition.

The elastic member 70 can be operatively joined to the nonwoven webs 72and 74, by using either an intermittent bonding configuration or asubstantially continuous bonding configuration. Herein, “intermittently”bonded laminate web means a laminate web wherein the plies are initiallybonded to one another at discrete spaced apart points or a laminate webwherein the plies are substantially unbonded to one another at discretespaced apart areas. Conversely, a “substantially continuously” bondedlaminate web means a laminate web wherein the plies are initially bondedsubstantially continuously to one another throughout the areas ofinterface. The stretch laminate may be bonded over all or a significantportion of the stretch laminate so that the inelastic webs (i.e., thenonwoven webs 72 and 74) elongate or draw without causing rupture, andthe layers of the stretch laminates may be bonded in a configurationthat maintains all of the layers of the stretch laminate in relativelyclose adherence to one another after the incremental mechanicalstretching operation. Consequently, the elastic panel members and theother plies of the stretch laminate may be substantially continuouslybonded together using an adhesive. In one embodiment, the adhesiveselected is applied with a control coat spray pattern at a basis weightof about 7.0 grams/square m. The adhesive pattern width may be about 6.0cm. The adhesive may be available from Nitta Findley Co., Ltd., Osaka,Japan, under the designation H2085F. Alternatively, the elastic panelmember and any other components of the stretch laminates may beintermittently or continuously bonded to one another using heat bonding,pressure bonding, ultrasonic bonding, dynamic mechanical bonding, or anyother method as is known in the art.

After the elastic member 70 is operatively joined to at least one of thenonwoven webs 72 and 74, at least a portion of the resultant compositestretch laminate may then be subjected to mechanical stretchingsufficient to permanently elongate the non-elastic components which are,for example, the nonwoven webs 72 and 74. The composite stretch laminatemay then allowed to return to its substantially untensioned condition.At least one pair of both of the ear panels 45, 46 and 48 may thus beformed into “zero strain” stretch laminates. (Alternatively, the elasticmember 70 could be operatively joined in a tensioned condition and thensubjected to mechanical stretching) Herein, “zero strain” stretchlaminate refers to a laminate included of at least two plies of materialwhich are secured to one another along at least a portion of theircoextensive surfaces while in a substantially untensioned (“zerostrain”) condition; one of the plies including a material which isstretchable and elastomeric (i.e., will return substantially to itsuntensioned dimensions after an applied tensile force has been released)and a second ply which is elongatable (but not necessarily elastomeric)so that upon stretching the second ply will be, at least to a degree,permanently elongated so that upon release of the applied tensileforces, it will not fully return to its original undeformedconfiguration. The resulting stretch laminate is thereby renderedelastically extensible, at least up to the point of initial stretching,in the direction of initial stretching. Methods and apparatus used formaking stretch laminates utilize meshing corrugated rolls tomechanically stretch the components. Apparatus and methods are disclosedin U.S. Pat. Nos. 5,167,897, 5,156,793 and 5,143,679.

Referring to FIG. 6, the absorbent article may comprise multiple zones250, including a side zone 251 (which may be further divided into rightand left, and front and back), a central zone 252 (which may be furtherdivided into front, middle, and hack), a waist hand zone 253, and legband zones 254 (which may be further divided into left and right). Eachof the expressed zones may be further divided into a viewablebody-facing surface and a viewable outer-facing surface. Zones 250 mayoverlap. Further, a zone 250 may comprise one or more absorbent articlecomponents (not shown in FIG. 6).

An absorbent article (e.g., 20) may comprise multiple components (e,g,256), many of which have been mentioned, described, and illustrated thusfar, including, but not limited to, an absorbent core (e.g., 25), an earpanel (e.g., 46, 48), a landing zone, a topsheet (e.g., 24), anacquisition layer, a core cover, a fastener (e.g., 370), a dustinglayer, a body side liner, an outer cover (e.g., 22), a core outer layer,waist members (e.g., 50), leg cuffs (e.g., 52), wetness sensationliners, a waist pocket member, a sensor or indicator (including wetnessand fit), a sustained fit element, a stiffener, a removable absorbentmember, an anchoring band, as well as, those absorbent articlecomponents mentioned, described, and illustrated in U.S. Pat. Nos.5,569,234, 6,443,940, 4,892,536, 4,990,147, 5,037,416, 5,269,775,4,515,595, 4,710,189, 5,151,092, 5,221,274, 3,848,594, 4,662,875,4,846,815, 4,894,060, 4,946,527, 5,151,092, 5,221,274, 6,432,098,4,699,622, 6,428,526, 3,860,003, 5,554,145, 5,569,234, 5,580,411,6,004,306, 5,246,433, 6,120,487, 6,120,489, 4,940,464, 5,092,861,5,897,545, 5,957,908, and U.S. patent application Ser. Nos. 10/222,438,10/815,918, 11/599,851, 11/541,325, and 11/599862. Absorbent articlecomponents (e.g., 256) may comprise multiple layers. Also, while theabsorbent articles (e.g., 20) above are described as pants, the presentinvention may also be in the form of a taped absorbent article (notshown). Absorbent article zones (e,g, 250) or components (e.g., 256) maybe attached to other zones (e.g., 250) or components (e.g., 256) usingvarious bonding means (including, adhesive, fusion, ultrasonic, hotneedle, wave, and other means described above). As described above,these bonds (e.g., 32) may be designed to fail upon a specific force(e.g., breaking the bond (e.g., 32) of two ear panels (e,g., 46 and 48)on a pant style absorbent article (versus tearing through the materialof the ear panel (e.g., 46 and 48)). Alternatively, zones (e.g., 250) orcomponents (e.g., 256) may be attached via fasteners (e.g., 370, FIG.11) which are detachably reattachable (including, hooks/loops,adhesives, buttons, latches, snaps, etc.) For instance, a first earpanel (e.g., 46) may comprise hooks and a second ear panel (e.g., 48)may comprise loops such that the two side panels may be attached anddetached several times. Without regard to the means, seams (e.g., 258)are formed when zones (e.g., 250) or components (e.g., 256) are attachedto other zones (e.g., 250) or components (e.g., 256).

Absorbent article zones (e.g., 250), components (e.g., 256), or thematerials (e.g., 124) comprised therein, may be stretchable, elastic, orextensible. For example, in one embodiment, an absorbent article (e.g.,20) may comprise stretchable, elastic, or extensible side zones 251, butits central zone (e.g., 252) may not be stretchable, elastic, orextensible. In another embodiment, an absorbent article (e,g., 20) maycomprise central and side zones (e.g., 252 and 251), both of which arestretchable, elastic, or extensible.

In one embodiment, an absorbent article (e.g., 20) may comprise astretchable, elastic, or extensible first component (e.g., an ear panel46 and 48), but a second component (e,g., an outer cover 22) may not bestretchable, elastic, or extensible. This may include an absorbentarticle (e.g., 20) that has stretchable, elastic, or extensible earpanels (e.g., 46 and 48) or side zones (e,g, 251) and a non-stretchable,non-elastic, or non-extensible central zone (e.g., 252). This may alsoinclude an absorbent article (e.g., 20) that has a stretchable, elastic,or extensible central zone (e.g., 252) and non-stretchable, non-elastic,or non-extensible ear panels (e.g., 46 and 48). In another embodiment,an absorbent article (e,g., 20) may comprise multiple components (e.g.,256) which are stretchable, elastic, or extensible (e.g., both an earpanel 46 and 48, and an outer cover 22).

Absorbent article zones (e,g., 250) or components (e.g., 256) maycomprise one or a combination of stretch-thermal laminates (STL),neck-bonded laminates (SBL), reversibly necked laminates, and/or astretch-bonded laminates (SBL), as well as elastomers described in U.S.Pat. Nos. 4,663,220 and 5,226,992, and European Pat. No. 0 217 032.Further, absorbent article components (e.g., 256) may comprise one or acombination of styrene-olefin-styrene block copolymers (including,styrene-butadiene-styrene (S-B-S), styrene-ethylene/butylene-styrene(S-EB-S), styrene-ethylene/propylene-styrene (S-EP-S),styrene-isoprene-styrene (S-I-S), hydrogenatedpolystyrene-isoprene/butadiene-styrene (S-IB-S)), polypropylene,polyethylene, polybutadiene, polyisoprene,polystyrene-ethylene/butylene-polystyrene block copolymers,polystyrene-ethylene-ethylene/propylene-styrene (SEEPS) blockcopolymers, styrenic-olefinic block copolymers, thermoplastic polymers(including, polyphenylene oxide and vinylarene resins derived frommonomers including styrene, α-methyl styrene, other styrene derivatives,and vinyl toluene), as well as elastomers described, in U.S. Pat. No.6,617,016.

Absorbent article zones (e.g., 250), components (e,g., 256), or thematerials (e.g., 124) comprised therein, may be able to stretch to anelongated length of at least about 110%, or about 125% of its relaxed,original length (i.e. can stretch to about 10 percent, or about 25% morethan its original length), without rupture or breakage, and upon releaseof the applied force, may recover at least about 40% of its elongation,or at least 60% of its elongation, or about 80% of its elongation. Forexample, a material (e.g, 124) that has an initial length of 100 mm mayextend to at least about 110 mm, and upon removal of the force wouldretract to a length of about 106 mm (40% recovery).

Absorbent article zones (e.g., 250), components (e.g., 256), or thematerials (e.g., 124) comprised therein, may have a permanent set (i.e.,percent set or set) less than about 60%, less than about 50%, less thanabout 40%, less than about 30%, less than about 20%, less than about15%, less than about 10%, less than about 5%, less than about 3%, lessthan about 2%, or less than about 1%. Absorbent article zones (e.g.,250), components (e.g., 256), or the materials (e,g., 124) comprisedtherein, or portions thereof, may be treated to be made stretchable,elastic, or extensible (or more stretchable, elastic, or extensible).Treatments may include ring-rolling and SELFing (as further described inU.S. Pat. Nos. 4,463,045 and 5,554,143, as well as electronic beamcross-linking.

Absorbent article components (e.g., 256) may comprise one or moregraphics (e.g., 10), and may more particularly be referred to as“graphic absorbent article components” (e.g., 9260, see FIG. 13).Graphics (e.g., 10) may include, but not limited to, letters, numbers,symbols, icons, mammal representations, animal representations, insectrepresentations, fish representations, vehicle representations,geometric shapes (e.g., circles, triangles, squares, rectangles,straight and wavy lines, etc.), animations, photographic images, plantrepresentations, landscape representations, patterns (symmetrical orrandom), textile-like prints or patterns, foliage representations,anthropomorphic representations, as well as those graphics described inU.S. Pat. Pub. No. 2006/0247594.

Additionally, graphics (e.g., 10) may be instructional (see FIGS. 19 and20). For instance, graphics (e.g., 10) may illustrate how to attach ordetach absorbent article components (e.g., 256) to or from one another.Graphics (e.g., 10) which are instructional may include a handrepresentation 360, a zipper representation, etc. Additionally,referring to FIG. 19, whole graphics 1322 and 1322′ which areinstructional (providing either a common instruction or two differentinstructions) may be oriented on each of the ear panels 2146 and 2148,such that each of the whole graphics 1322 and 1322′ are on each side ofthe seam 2258. In FIG. 19, graphics 1322 and 1322′ are providing thecommon instruction of disengaging the side panels 3046 and 3048. Also,one or a plurality of whole graphics (e.g., 1322 and 1322′) which areinstructional, providing a common instruction, may be located on asingle ear panel (e.g., 3046). Still further, referring to FIG. 20, aninterrupted graphic 1324 which is instructional, providing a commoninstruction, may be oriented across the seam 2258 of two side panels3046 and 3048. Other graphics (e.g., 10) which provide instructions mayhe found in U.S. patent application Ser. No. 11/541,325 (Ashton et al.),U.S. patent application Ser. No. 11/198,614 (Liu et al.), U.S. patentapplication Ser. No. 11/083,606 (Roe et al,), U.S. patent applicationSer. No. 11/083,607 (Roe et al.), and U.S. Patent Publication No.2005/0096618 (Magee et al.).

Graphics (e.g., 10) may be applied to absorbent article components(e.g., 256) using a number of printing techniques and processes,including, but not limited to, relief printing (including letterpressand flexography), planographic printing (including offset lithography,screenless lithography, collotype, and waterless printing), intaglioprinting (including gravure, steel-die, and copper-plate engraving),stencil and screen printing, and electronic printing (includingelectrostatic, magnetographic, ion or electron deposition, and ink-jetprinting). Graphics (e.g., 10) may be applied to absorbent articlecomponents (e.g., 256) in the absorbent article component's (e.g., 256)relaxed or stretched state (in the case of stretchable, elastic, orextensible graphic absorbent article components (e.g., 260)), as furtherdescribed in U.S. Pat. No. 5,612,118.

In flexography printing, graphics (e.g., 10) are formed via a raisedsurface on a printing plate. The raised surface is inked using auniformly engraved/etched anilox roll. The anilox roll picks up ink froman ink fountain and transports it onto the printing plate. Printing isdone by transferring the ink directly from the printing plate to thesubstrate (e.g., outer cover 22).

Gravure printing is accomplished by cutting, engraving, or etchingvarious sizes and/or depths of minute cells (or wells) below a surfaceof a plate or cylinder. The cells are flooded and loaded with ink, theexcess ink is scraped off the surface of the plate by a doctor blade,and the ink left in the cells is transferred to a substrate. The depthand size of each cell determines the amount of ink that is transferredto the surface of the plate. The nature of the process permits a heavylaydown of ink, which accounts for the rich, saturated colors typical ofthe gravure process.

The sequence of steps in both floxography and gravure is prepress, pressor print, and postpress. The prepress and postpress operations aresimilar for floxography and gravure including the design, preparation,and assembly of graphics (e.g., 10) for reproduction, the finishingoperations to give the final substrate, winding and transportation. Theprinting press unit has a print cylinder for mounting the plate, aninking system to feed ink to the plate, an impression cylinder toprovide backing pressure and support for the substrate as the graphic isprinted onto it from the printing plate. The press has a means forfeeding the substrate (unwinding unit) into printing units, and adelivery device for collecting the printed substrate (the rewind). Thepress has as many printing units as the number of colors that it canprint (e.g., a four-color press for example has four printing units).

The following graphic (e.g., 10) configurations may be of interest tohighlight the dynamic nature of the graphics (e.g., 10):

Graphic Configuration 1

Referring to FIGS. 7A and B, a graphic 1010, 2010, and 3010 may comprisea character's main body 264 and 1264 oriented on the central zone 252 ofthe absorbent article 20 and the character's arms 266 and 1266 (or otherextremities of the character, including legs and tails) extending fromthe character's main body 264 and 1264 to the side zones 251 of theabsorbent article 20. The central zone 252 of the absorbent article 20generally includes the area bounded by the width (transverse) of theabsorbent article 20 in the crotch region 30 to the waist bands 50 inboth the front region 26 and the back region 28 forms the waist opening36. However, the central zone 252 may also be generally defined by achange in an elastic modulus of the zones 250. In this configuration,the side zones 251 may comprise a material (e.g., 124) which isstretchable, elastic, or extensible so that, in use, the character'sarms 266 and 1266 may change shape, aspect ratio, or visual appearanceas a result of the side zone's 251 elastic modulus during wear orapplication.

Graphic Configuration 2

Referring to FIG. 8, a graphic 4010 may comprise a character's main body3264 oriented on the central zone 252 of the absorbent article 20 andseparate, but complementary graphics 4010 may be oriented on the sidezones 251 of the absorbent article 20. For instance, a cartoon of alittle girl and plant representations 268 may be oriented on the centralzone 252 of the absorbent article 20 and flower and plantrepresentations 270 may be oriented on the side zones 251 of theabsorbent article 20. This configuration may give the impression thatseparate zones 250 or components 256 of the absorbent article 20 do notexist.

Graphic Configuration 3

Frames of a story (not shown) may be placed on different zones (e.g.,250) or components (e.g., 256) of an absorbent article (e.g., 20). Thestory may evolve from frame to frame. For example, a story may start ina frame oriented on a right side zone (e.g., 272 (relative to thewearer)) and may progress (counterclockwise) to a front central zone(e.g., 274), to a left side zone (e.g., 276 (relative to the wearer)),to a back central zone (e.g., 278), and back to the right size zone(e.g., 272). Alternatively, a story may progress in the oppositedirection (clockwise). Counterclockwise may be more easily understood byan observer of a wearer. Additionally, it should be understood thatgraphics (e.g., 10) may be oriented right-side-up (relative to thewearer) or upside-down (relative to the wearer).

Graphic Configuration 4

Referring to FIG. 9, graphics 5010 may be oriented in one or both theleg band zones 254 and the waist band zone 253 such that, when theabsorbent article 20 is being worn, an element appears to enclose theleg and/or waist openings 34 and 36 of the absorbent article 20. Asillustrated FIG. 9, “representative of a leg band” means graphics 5010that resemble the look of leg bands on male or female underwear boxers,trunks, briefs, or panties. Likewise, as illustrated FIG. 9,“representative of a waist band” means graphics 5010 that resemble thelook of waist bands on male or female underwear boxers, briefs, briefs,or panties.

Alternatively, rather than using graphics 5010 to create the appearanceof a leg band or a waist band (as they exist on underwear), separateabsorbent article components (e.g., 256) may be bonded or fastened tothe outer cover 22. Said separate components (e.g., 256) may befunctional and/or aesthetic. Said separate components (e.g., 256) maycomprise an elastomer and may be stretchable, elastic, or extensible.Said separate components (e.g., 256) may be actual leg and waist bands.

Graphic Configuration 5

Referring to FIGS. 10A-C, multiple graphic absorbent article components6260, 7260, and 8260 may be oriented in an overlapping manner such thatat least portions of graphics 6010, 7010, and 8010 of overlappedcomponent 6260, 7260, and 8260 can be seen through the overlappingcomponent 6260, 7260, and 8260. Further, portions of the graphicabsorbent article components 6260, 7260, and 8260 may be connected toeach other such that the graphic absorbent article components 6260,7260, and 8260 are capable of moving relative to each other as theabsorbent article 20 is being worn by a wearer. For example, a charactergraphic 288, 1288, and 2288 (or a portion thereof) may be oriented onthe absorbent core 25 and flower and plant representations 1270, 2270,and 3270 may be oriented on the outer cover 22 such that when theabsorbent article 20 is worn, the outer cover 22 moves relative to theabsorbent core 20, and, because one is able to at least partially seethe character graphic 288, 1288, and 2288 on the core 20 through theouter cover 22, it appears to that the character graphic 288, 1288, and2288 is peeking out between the flower and plant representations 1270,2270, and 3270.

In order to achieve a more underwear-like absorbent article (e.g., 20),graphic absorbent article components (e.g., 260) may be complemented byadditional absorbent article (e.g., 20) features (not shown), including,but not limited to, a robust leg band or waist hand feature (see U.S.Pat. No. 5,064,421), a narrow crotch dimension (from about 7 cm to about16 cm, or from about 10 cm to about 12 cm), an outer cover thatcomprises an elastomeric material, such that it conforms to the shape ofthe wearer, a fixed side seam (see U.S. Pat. No. 5,779,831), a visual orphysical tag on the article (including, garment care instruction tags,garment composition tags), and an absorbent article shape that iscreated to closely follow the anatomical dimensions of the wearer.

An absorbent article (e.g., 20) may comprise graphics (e.g., 10) on asubstantial portion of the surface area of the inner and/or outer-facingsurface (e.g., 24 and 22) of the absorbent article (e.g., 20). Thesurface area of the absorbent article (e.g., 20) would he defined as thearea which is visible to the eye when the article is stretched out on aflat surface. This would apply for both the inner and/or outer-facingsurface (e.g., 24 and 22) of the absorbent article (e,g., 20).

For example, an absorbent article (e.g., 20) may comprise graphics(e.g., 10) on at least about 50%, about 75%, about 85%, about 90%, about95%, or about 100% of its viewable outer surface.

An absorbent article (e.g., 20) may comprise graphics (e.g., 10) on atleast about 50%, about 75%, about 85%, about 90%, about 95%, or about100% of its viewable inner surface. An absorbent article (e.g., 20) maycomprise graphics (e.g., 10) on at least about 50%, about 75%, about85%, about 90%, about 95%, or about 100% of its combined viewable innerand outer surfaces, Alternatively an absorbent article (e.g., 20) maynot comprise graphics (e.g., 10) on a substantial portion of the surfacearea of the inner and/or outer-facing surface (e.g., 24 and 22) of theabsorbent article 20, but may comprise graphics (e.g, 10) on severalabsorbent article components and/or zones (e.g., 256 and/or 250) overthe surface area of the viewable inner and/or outer-facing surfaces in aformat which gives the impression that graphics (e.g., 10) are on asubstantial portion of the surface area of the inner and/or outer-facingsurface (e.g., 24 and 22) of the absorbent article 20.

For example, an absorbent article (e.g., 20) may comprise graphics(e.g., 10) on at least about 25%, about 50%, 75%, about 85%, about 90%,about 95%, or about 100% of its viewable outer absorbent articlecomponents. For instance, as illustrated in FIG. 10-A, the graphics 8010on the absorbent core 25, as well as the graphics 8010 on the outercover 22 are viewable, and should be considered viewable outer absorbentarticle components comprising graphics. An absorbent article (e.g., 20)may comprise graphics (e,g., 10) on at least about 25%, about 50%, about75%, about 85%, about 90%, about 95%, or about 100% of its viewableinner absorbent article components. An absorbent article (e.g., 20) maycomprise graphics (e.g., 10) on at least about 25%, about 50%, about75%, about 85%, about 90%, about 95%, or about 100% of its combinedviewable inner and outer absorbent article components.

For example, an absorbent article (e.g., 20) may comprise graphics (e.g,10) on at least about 25%, about 50%, 75%, about 85%, about 90%, about95%, or about 100% of its viewable outer absorbent article zones. Anabsorbent article (e.g., 20) may comprise graphics (e.g., 10) on atleast about 25%, about 50%, about 75%, about 85%, about 90%, about 95%,or about 100% of its viewable inner absorbent article zones, Anabsorbent article (e.g., 20) may comprise graphics (e.g., 10) on atleast about 25%, about 50%, about 75%, about 85%, about 90%, about 95%,or about 100% of its combined viewable inner and outer absorbent articlezones.

Absorbent articles (e.g., 20) of the present invention may comprise acontinuous or substantially continuous outer cover (e.g., 22) to whichgraphics (e,g., 10) are applied. The outer cover (e.g., 22) may then becut for shape purposes in a final finishing process before it is formedas part of the finished absorbent article (e,g., 20). In order topreserve the design integrity of the graphics (e.g., 10) on a finishedabsorbent article (e.g., 20), the outer cover (e.g., 22) may be cut inthe final finishing process at a precise point of the outer cover (e.g.,22). Methods and equipment for constructing such absorbent articles(e.g., 20) may be found in U.S. Pat. Nos. 5,569,234 and 5,659,538. Anadvantage to constructing the absorbent article (e.g., 20) with acontinuous graphic absorbent article component (e.g., 260) is a lowernumber of visible seams (e.g., 258).

Absorbent articles (e.g., 20) of the present invention may utilize oneor more components located in a central zone (e.g., 252) for attachinggraphic absorbent article components (e.g., 260) to (see FIG. 11).Graphic absorbent article components (e.g., 260) may be attached suchthat the graphic absorbent article components (e.g., 260) are entirelycontained within the area of a central zone (e.g., 252) or such that oneor more edges of a graphic absorbent article components (e.g., 260) areattached to one or more components located in a central zone (e.g.,252). Methods and equipment for constructing such absorbent articles aredescribed in U.S. Pat. Nos. 4,940,464 and 5,224,405.

In order to ensure that absorbent article components (e.g., 256(including graphic absorbent article components (e.g., 260)) areproperly oriented when attached to other absorbent article components(e.g., 256), registration may be used. Registration may include using asystem (e.g., 298, see FIG. 12) to detect a location (e.g., A, B, and C,see FIG. 11) on an absorbent article component (e.g., 256) and tocompare the location (e.g., A, B, and C) against a set point (which maybe an operator desired or machine set location). The system (e.g., 298)may adjust placement of the absorbent article component (e.g., 256) inaccordance with said comparison. For example, the location (e,g, A, B,and C) of a series of graphics (e.g., 10) on an outer cover (e.g., 22)may be detected and a repeat length of the graphics (e.g., 10) may bealtered via a length control system (not shown, but described in U.S.Pat. Nos. 6,444,064 and 6,955,733). Alternatively, a system (e.g., 298)may be used to detect and control the longitudinal or machine directionposition of a component (e.g., 256) relative to a desired position onthe absorbent article (e.g., 20) wherein the position at whichsubsequent occurrences of a first component (e.g., 256) is attached to asecond component (e,g., 256) is altered to ensure the first component(e.g., 256) is in the desired location. Such can be performed based onmultiple detections and the use of an average position, deviation fromthe desired position, or by detecting less frequently than everyoccurrence.

Additionally, a system (e.g., 298) may detect a first location (e.g., A)on a first absorbent article component (e.g., 256) and a second location(e.g., B), on a second absorbent article component (e.g., 256). Thefirst and second locations may be compared relative to each other andagainst a set point or desired offset position. The system (e.g., 298)may adjust placement of the first and/or second absorbent articlecomponents in accordance with said comparison. For example, a throughbeam vision system may take an image of the absorbent article (e.g.,20), determine a first location (e.g., A) of a leading edge (e.g., 306,see FIG. 11) of an absorbent core (e.g., 1025), and a second location(e.g., B) of a trailing edge (e.g., 308) at ear panel (e.g., 2046). Saidsystem (e.g., 298) may then determine the difference in position betweenthe two absorbent article components in the machine direction (e.g.,310) and compare the difference against a set point or desired offset.Based on the difference between the comparison and the set point, thesystem (e.g., 298) may determine that a corrective action is requiredand initiate that corrective action to change the relative position ofthe ear panel (e.g., 2046) on subsequent absorbent articles (e.g., 20).

It may be desirable to use a combination of detection methods. Forexample, a photographic image system (e.g., 302) may be used to detectone or more locations (e.g., A, B, and C) on an outer facing absorbentarticle component (e.g., 256), such as an outer cover (e.g., 1022) and athrough beam radiation system (e.g., 300) may be used to detect one ormore locations (e.g., A, B, and C) on an inner absorbent articlecomponent (e.g., 256), such as a topsheet (e.g., 24). Additionally, itmay be possible to detect graphics (e.g., 8010) with a photo eye orphoto optic. For example, a photographic image system (e.g., 302) may beused to detect a graphic (e.g., 8010) location (e.g., C) on an outercover (e.g., 1022), and a graphic (e.g., 8010) on an ear panel (e.g.,2046), while a through beam system (e.g., 300) could detect the positionof an absorbent core (e.g., 25).

Referring to FIGS. 11 and 12, a system 298 may detect a location A, B,and Con each of three or more absorbent article components 1256. Thedetected locations A, B, and C may be compared against one or more setpoints. The detected locations A, B, and C may also be compared relativeto each other and then against one or more set points. The system 298may adjust placement of two or more of the detected absorbent articlecomponents 1256 in accordance with said comparison. For example, asillustrated in FIG. 12, a machine vision system 298 comprising twovision capture devices 300 and 302 may he used. One vision capturedevice 300 may be located on the opposite side of a light emittingdevice 304, and one capture device 302 may be located on the same sideas the light emitting device 304. In this example, the vision capturedevice 300 on the opposite side of the light emitting device maygenerate a through beam image to determine the location of, for example,an edge 306 of an absorbent core 1025 and an edge 308 of an ear panel2046. The vision capture device 302 on the same side as the lightemitting device 304 may generate a reflected image to determine thelocation of graphics 8010 on an outer cover 1022 of the absorbentarticle 1020. The resulting images may be processed to determine, theabsolute and relative positions of the three locations A, B, and C andthe positions could be compared to each other and against a set point ordesired offset. From the comparison of the relative component 1256positions and the set points or desired offsets, the system 298 woulddetermine if a corrective action is required. If a corrective action isrequired, the system may initiate the corrective action for one or moreof the components 1256 to ensure the absolute or relative positions ofthe components 1256 on subsequent absorbent articles 1020 is within theset point or desired offset tolerances.

Examples of components 1256 on which one or more locations A, B, and Ccould be detected and processed using such a system 298 may include, butnot be limited to, an absorbent core (e.g., 1025), an ear panel (e.g.,2046, 2048), a landing zone, a topsheet (e.g., 24), an acquisitionlayer, a core cover, a fastener (e.g., 370), a dusting layer, a bodyside liner, an outer cover (e.g., 1022), a core outer layer, waistmembers (e.g., 50), leg cuffs (e.g., 52), wetness sensation liners, awaist pocket member, a sensor or indicator (including wetness and fit),a sustained fit element, a stiffener, a removable absorbent member, ananchoring band, or other components (e,g., 1256) that may be detectedusing through beam, photo eye, or reflected image vision systems.Possible combinations of components could include, but not be limitedto, the following component combination sets: (1) an absorbent core(e.g., 1025), an ear panel (e.g., 2046 and 2048), a graphic (e.g., 8010)on an outer cover (e.g., 1022); (2) an ear panel (e.g., 2046 and 2048),a graphic (e.g., 8010) on an outer cover (e.g., 1022), a waist member(e.g., 50); (3) an absorbent core (e.g., 1025), an ear panel (e,g., 2046and 2048), a waist member (e.g., 50); (4) a graphic (e.g., 8010) on anouter cover (e.g., 1022), an ear panel (e.g., 2046 and 2048), a graphic(e.g., 8010) on a waist member (e.g., 50); (5) combinations of “(1)”through “(4)” within this paragraph, as well as those combinationsreadily apparent to those skilled in the art.

Beyond using the above registration systems (e.g., 298), it may bedesirable to control the inline position of graphics (e.g., 8010 (seeU.S. Pat. No. 6,444,064)) into a discrete absorbent article componentplacement device (see U.S. Pat. No. 5,224,405) to ensure the placementdevice does not cut through, disturb, or otherwise negatively impact thegraphics (e.g., 8010) on the absorbent article component (e.g., 1256)being applied by the placement device. This method may be combined witha system (e.g., 298) which ensures the proper placement of the absorbentarticle components (e.g., 1256) described above or with similar systems(e.g., 298). Said combination may be used to produce an absorbentarticle (e.g., 1020) comprising graphics (e.g., 8010) aligned relativeto each other such that the absorbent article (e,g., 1020) appears moreholistic and garment-like.

It may be further (or alternatively,) desirable to combine the aboveregistration systems (e.g., 298) and methods with the methods describedin U.S. Pat. Nos. 5,659,538, 7,123,981, 5,359,525, 6,743,314, 5,659,538,6,957,160, 5,980,087, 6,253,159, 6,266,436 and 6,224,699.

Beyond considerations related to the physical construction of absorbentarticle components (e.g., 256), such as choice of absorbent articleconstruction, registration, etc., there are several designconsiderations for overcoming the negative impact seams (e,g., 1258) maycreate for an absorbent article (e.g., 20) designed to appear moreholistic and garment-like.

Referring to FIG. 13, a graphic 9010 may comprise wavy lines 306(including undulating or irregular lines) on the back ear panel 2048which overlaps the front ear panel 2046 comprising wavy lines 306 toform a seam 1258. Wavy lines 306 on each of the ear panels 2048 and 2046may be used to disguise any misalignment of the first and second graphicabsorbent article components 9260.

Referring to FIG. 14-A, graphic absorbent article components 260 maycomprise color fields 316 and 318 which is not part of the graphic 10.More specifically, the front ear 46 may comprise the color field 316which gradates and which may overlap the back ear 48 comprising thecolor field 318 which gradates. Further, the color fields 316 and 318 onthe ear panels 48 and 46 may be similar for the purpose of disguisingany misalignment of the ear panels 48 and 46. Further, as illustrated inFIGS. 14A and B, color fields 316, 1316, 318, and 1318 may run along thewaist opening 36, in the waist band zone 253, and gradate in thetransverse direction away from the waist opening 36. FIG. 14-Cillustrates a color field 320 which runs in the longitudinal directionalong the seams 258, and which gradates in the transverse direction awayfrom the seam 258. Similarly gradating color fields (e.g., 316, 318,1316, 1318, and 320) may help to disguise any misalignment of thegraphic absorbent article components 260.

Referring to FIGS. 15A and 15B, a graphic 10010 may comprise wholegraphics 322 on the back ear panel 2048 which overlaps the front earpanel 2046 comprising whole graphics 322 to form a seam 1258. This alonewill enhance the garment like appearance of the final absorbent article(e.g., 1020). Further, each of the whole graphics 322 may be oriented oneach of the respective graphic absorbent article components 10260 suchthat no whole graphics 322 are interrupted (cut-off like as graphics 324are, as illustrated by FIG. 15C) by the overlapping of the first andsecond graphic absorbent article components 10260.

Referring to FIGS. 16A and B, graphics 11010 and 12010 may be orientedon graphic absorbent article components 11260 and 12260 in an organized(uniform and symmetrical) or random fashion. Random orientation ofgraphics 12010 on the back ear panel 2048 which overlaps the front earpanel 2046 which comprises randomly oriented graphics 12010 may disguiseany misalignment of graphics 12010 which are interrupted by finishingprocesses and/or by seams 1258 (versus organized graphics 11010). Randomorientation of graphics 12010 on graphic absorbent article components12260 may appear more garment like and may be offer synergy with graphicabsorbent article components (e.g., 10260) comprising only wholegraphics (e.g., 322).

Referring to PEG. 17, the impact of the seam 1258 may also be lessenedby keeping the distance between a graphic 13010 and the seam 1258 small.More specifically, it may be desirable to (1) keep a distal point 326 onthe graphic 13010 close (between about 2 cm and about 0.2 cm, betweenabout 1.7 cm and about 0.5 cm, between about 1.5 cm to about 0.7 cm,between about 1.2 cm and about 1 cm) to an overlapped edge 10240 of thefront ear panel 2046, Distance D-1, and/or (2) keep a distal point 326′on the graphic 13010 (between about 2 cm and about 0.2 cm, between about1.7 cm and about 0.5 cm, between about 1.5 cm to about 0.7 cm, betweenabout 1.2 cm and about 1 cm) to an overlapping edge 10240 of the backear panel 2048, Distance D-2. Because of standard deviations in themanufacturing process, particularly as a first graphic absorbent articlecomponent (e.g., 13260) is attached to a second graphic absorbentarticle component (e.g., 13260), getting a graphic too close to the seammargin may result in a cut-off graphic (e.g., 324).

A color of a first graphic absorbent article component (e.g., 13260),whether part of the graphic (e.g., 13010) or as color field (e.g., 318),may be matched to a color of a second graphic absorbent articlecomponent (e.g., 13260), whether part of the graphic (e.g., 13010) or acolor field (e.g., 318). Said color match may be based on a CM ΔE (ASTMD2244-05), such that no difference is readily discernable to the eyeacross a seam (e.g., 1258). U.S. Pat. Pub. No. 2006/0025737 describescolor matching in greater detail.

The appearance of a waistband (e.g., graphic 5010 in the waist band zone253) may take attention away from seams (e.g., 1258) of an absorbentarticle (e.g., 1020). The visual appearance of a waistband (e.g.,graphic 5010 in the waist band zone 253) on an absorbent article (e,g,1020) may be created or highlighted by a color field (e.g., 318) orgraphic (e.g., 5010) generally in the waist band zone (e.g., 253). Thismay be accomplished multiple ways, including coloring elastic strands ora film in the waist band zone (e.g., 253), printing a colored band orgraphic (e.g., 5010) in the waist band zone (e.g., 253), printing acolor gradation (e.g., 318) in the waist band zone (e,g., 253), tintinga base substrate (e.g., a nonwoven) in the waist band zone (e.g., 253),or placing a single colored component (e.g., 1256) all the way aroundthe absorbent article (e.g., 20) in the waist had zone (e.g., 253).

One or more seams (e.g., 1258) of an absorbent article (e,g, 1020) maybe hidden by printing or coloring the plurality of absorbent articlecomponents (e.g., 1256) after some or all of them have been assembled.Such may be accomplished using a contact printing method (e.g., gravure,flexography, dyeing, etc.) or with a non-contact method (e.g., ink jetprinting). The benefit of a non-contact method is that the printing orcoloring would be less sensitive to the surface texture of the absorbentarticle components (e.g., 1256) being printed on. The seam (e,g., 1258)would be directly printed across, eliminating or significantlyminimizing the presence of any discontinuity between the connectedabsorbent article components (e.g., 1256).

In some instances, as illustrated in FIG. 18, an absorbent article 2020construction may decrease or eliminate seams (e.g., 1258). For instance,an outer cover 2022 may cover most or all of the seams (e,g., 1258) ofthe absorbent article 2020. Additionally, instead of having ear panels(e.g., 2048 and 2046) which meet each other to forma a seam (e.g., 1258)in the middle of a side zone 1251, a single piece ear panel may be usedsuch that seams (e.g., 1258) border the transition from the side zone1251 to the central zone 1252. These seams (e,g, 1258) may bereattachably detachable.

It may, in such cases, be desirable to design graphics 14010 whichhighlight the lack of a seam (e.g., 1258). It may desirable to implementdesigns in seamless areas that would be impractical to implement acrossa seam ((e.g., 1258) due to unacceptable appearance). The lack of a seam(e.g., 1258) may be highlighted by various design elements, including,but not limited to, transverse lines 330, diagonal patterns 332, andmulti-color repeat patterns.

In cases where a seam is present, the above techniques may be used tolessen the appearance of the seam. One may desire to measure theeffectiveness of the techniques. Described in more detail below is aconsumer method to perform this evaluation. Particularly, the belowconsumer method may be used to determine a Seam Noticeability Rating(SNR).

An SNR measures the visual impact of a seam formed in a side zone or aseam formed between the side zone and a central zone. The visual impactof seams impacts the consumer perception of underwear-likeness. Severalfactors affect the SNR, including, but not limited to, pattern, scale,vertical spacing, horizontal spacing, vertical offset, horizontaloverlap, contrast, and level of stretch. And, there may be interactionsbetween two or more of the factors.

It may be desirable to have an SNR of less than about 7 for one or moreseams, including a seam formed in a side zone, and including a seamformed between a zone and a central zone of the absorbent article.Further, it may be desirable for the SNR of a seam to be less than about6, about 5, about 4, or about 3.

The outer cover (e.g., 22) may also be used to help create an absorbentarticle (e,g, 20) that is more underwear like. Outer covers (e.g., 22)of the present invention may be entirely or partially stretchable orelastic in one or more directions. The outer cover (e.g., 22) may beimpervious to liquids (e.g., urine) and manufactured from a thin plasticfilm or a nonwoven web, although other flexible liquid imperviousmaterials that are compliant and will readily conform to the generalshape and contours of the human body can also be used. Additionally, insome embodiments, the outer cover (e.g., 22) may comprise a laminatedstructure.

The outer cover (e.g., 22) may be generally positioned such that it canbe at least a portion of the garment-facing surface of the absorbentarticle (e.g., 20). The outer cover (e.g., 22) can prevent the exudatesabsorbed and contained within the absorbent article (e.g., 20) fromsoiling articles that can contact the absorbent article (e.g., 20), suchas bed sheets and undergarments, in some embodiments. Suitable outercover materials include films such as those manufactured by TredegarIndustries Inc. of Terre Haute, Ind. and sold under the trade namesX15306, X10962, and X10964. In various embodiments, the outer cover(e.g., 22) can include an inelastic nonwoven. The outer cover (e.g., 22)can be a thermoplastic film having a thickness of from about 0.012 mm(0.5 mil) to about 0.051 mm (2.0 mils). Another example of a suitablefilm which can be utilized in the outer cover (e.g., 22) includes a0.5-1.0 mil (0.0005″-0.001″) thick Vistamaxx (elastomeric polypropylenefrom ExxonMobil). Example elastomeric polypropylene-based compositionsare disclosed in PCT App. Nos. WO 2005/052052 and WO 2005/097031. Theelastormeric composition may also include fillers like titanium dioxidefor improving opacity and calcium carbonate for breathability. Theelastomeric polypropylenes may also be blended with styrenic blockcopolymers, semicrystalline polyolefins or sub-micron inorganicparticles.

In some embodiments, the outer cover (e.g., 22) may comprise an elasticnonwoven. In some embodiments, the outer cover (e.g., 22) may comprise alaminate including an elastic nonwoven and a plastic film, for example,polyethylene film. In some embodiments, the outer cover (e.g., 22) maycomprise a laminate including an elastic film and a non-elasticnonwoven. Further, the outer cover (e.g., 22) may comprise a laminateincluding printed elastics. Still further, the outer cover (e.g., 22)may comprise a laminate including an elastic in the form of a scrim-likestructure or a crosshatch pattern that is joined between two layers of anonwoven or between a nonwoven and a breathable film (e.g., polyethylenefilm), etc.

The elastomeric film examples provided above can be laminated to atleast one layer of non-elastomeric or extensible nonwoven using spiralglue. Additionally, this laminate can be incrementally stretched in amachine direction and then in a cross machine direction thereby forminga biaxially stretchable elastic laminate (i.e., an elastic laminate thatis extensible in the orthogonal in-planar directions simultaneously, orsequentially). A suitable example of a nonwoven which can be utilized inthe outer cover (e.g., 22) includes deeply activatable poly propylene(DAPP). A suitable DAPP nonwoven is sold under the designation Softspan200 available from BBA Fiberweb, Brentwood Tenn. In some embodiments theDAPP can be joined to an elastic element, e.g., elastomeric scrim andjoined to a polyethylene film. In some embodiments, the DAPP can bejoined to an elastic element, e.g., elastomeric scrim and joined toanother DAPP nonwoven.

Outer cover (e.g., 22) laminates, such as those described above, wherethe elastormeric component is combined with another web in a relaxed,unstretched state, are referred to in the art as “zero-strainlaminates”. While in some embodiments, the zero-strain laminate may beinherently stretchable in a virgin state, the stretch properties ofthese materials are usually released or improved by mechanicalactivation, or incremental stretching, such as ring rolling or SELFing.Alternatively, pre-stretched laminate materials may also be employed asouter cover (e.g., 22) materials in the present invention. Pre-stretchedelastomeric outer covers (e.g., 22) are formed by applying anelastomeric material, e.g., strands or films, to a substrate while theelastomeric material is in a prestrained state, and subsequentlyallowing the laminate to relax and contract. Pre-stretched stretchableouter cover (e.g., 22) materials may be formed by applying pre-tensionedelastomeric elements in at least two different directions aligned withthe longitudinal and lateral axes of the article. In certainembodiments, outer covers (e.g., 22) of the present invention mayinclude both zero-strain and pre-stretched elastomers. For example, apre-tensioned elastomeric element may be affixed to a zero-strainelastomeric laminate either parallel to the zero strain laminate'sprimary direction of stretch or at an angle thereto.

In some embodiments, the outer cover (e.g., 22) may comprise anelastomeric layer which includes an elastomeric adhesive, e.g., a hotmelt pressure sensitive adhesive. In these embodiments, additionaladhesive may not be needed to bond the layers of the laminate together.However, if the elastomeric material does not have good adhesiveproperties, additional adhesive may be utilized.

In some embodiments, the outer cover (e.g., 22) may have a low force ata specific elongation as measured by the Hysteresis Test (50% MaximumStrain). Since the outer cover (e.g., 22) can have different stretchproperties in different directions, stretch properties in the HysteresisTest are measured in the longitudinal direction (machine direction),lateral direction (cross machine direction) and in a direction that isparallel to the length direction of the anchoring band (previouslymentioned at pages 16 and 27). In some embodiments, at least a portionof the outer cover (e.g., 22) may have a first cycle force less thanabout 20 gm/cm at 15% strain, a first cycle force less than about 15gm/cm at 15% strain, or a first cycle force less than about 10 gm/cm at15% strain.

Additionally, in some embodiments, the outer cover (e.g., 22) may alsohave a percentage set (as measured by the Hysteresis lest) which is lessthan about 40%. In some embodiments, the outer cover (e.g., 22) may havea percentage set which is less than about 30% or in some embodiments,less than about 15%.

In some embodiments, the outer cover (e.g., 22) may be sufficientlybreathable. For example, in some embodiments, the outer cover (e.g., 22)can be constructed to be permeable to at least water vapor and can havea moisture vapor transmission rate (MVTR) of at least about 1000 g/m²/24hr., at least about 1500 g/m²/24 hr., at least about 2000 g/m²/24 hr.,or at least about 3000 g/m²/24 hr. In other embodiments, the outer cover(e.g., 22) may have an MVTR of at least about 7000 g/m²/24 hr. In someembodiments, the outer cover (e.g., 22) may have a MVTR of from about1000 to about 8000 g/m²/24 hr. or any individual number within therange. Some breathable backsheet materials are described in greaterdetail in PCT App. No. WO 95116746; and U.S. Pat. Nos. 5,938,648,5,865,823 and 5,571,096. Other suitable exemplary materials and asuitable test method for measuring the MVTR are described in U.S. Pat.No. 6,448,467.

Additionally, in some embodiments, the outer cover (e.g., 22) maycomprise underwear-like texture/aesthetics. One aspect of underwear likeaesthetics is gloss (as measured according to ASTM D2457-97) to give apleasing matte look (not plastic like). A gloss value of 7 gloss unitsor less has been found desirable. Embossing and/or matte finishingimproves the outer cover's 22 gloss.

The outer cover (e.g., 22), in some embodiments, may have sufficientopacity such that exudates discharged into a core assembly cannot bereadily perceived from a vantage point external to the absorbent article(e.g., 20). Also, the outer cover (e.g., 22) may have sufficient opacityto prevent the skin from being seen in the non-core areas of theabsorbent article (e.g., 20). In order to increase the opacity ofstretchable outer cover (e.g., 22) elastic nonwovens, in someembodiments, at least one meltblown may be incorporated into thespunbond web. The meltblown layer may consist of nano-fibers. Themeltblown layer may have a basis weight of between about 1 gsm and about20 gsm or any individual number within the range. In some embodimentsthe meltblown layer may have a basis weight of between about 4 gsm andabout 15 gsm and may comprise various combinations of elastomeric andplastic polymeric resins. Higher elastomeric content may be preferredwhen higher depths of activation (incremental stretching) are requiredand/or when lower permanent set values in the outer cover (e.g., 22) aredesired. Elastomeric and plastic polyolefin combinations may utilized insome embodiments to optimize the cost/performance balance. In someembodiments, the elastomeric component may comprise a very lowcrystallinity polypropylene grade such as those commercialized byExxonMobil under the tradename Vistamaxx. Additionally, the elasticnonwoven structure may also include another spunbond layer that does notprovide significant elastic recovery, yet possesses sufficientextensibility to survive the activation process. Some suitable examplesof such extensible spunbond nonwoven layers are disclosed in PCT App.Nos. WO 2005/073308 and WO 2005/073309.

Other exemplary breathable materials can include materials such as wovenwebs, nonwoven webs, polymeric films such as thermoplastic films ofpolyethylene or polypropylene, composite materials such as film-coatednonwoven webs, and microporous films such as manufactured by MitsuiToatsu Co., of Japan under the designation ESPOIR NO and by EXXONChemical Co., of Bay City, Tex., under the designation EXXAIRE. Suitablebreathable composite materials comprising polymer blends are availablefrom Clopay Corporation, Cincinnati, Ohio under the name HYTREL blendP18-3097. An exemplary, suitable outer cover (e.g., 22) is disclosed inU.S. Pat. No. 6,107,537.

The stretchable outer cover (e.g., 22) can also be made by elastomerprinting, spraying, slot coating, meltblown or film lamination. Printingincludes gravure, flexographic, letterpress, screen, digital, or thelike. Some suitable examples of elastomer printing are described in U.S.Patent App. Pub. Nos. 2003/0088220A1; 2003/0088228A1; 2003/0091807A1;2004/0193133A1; 2004/0222553A1; 2005/0214461A1; 2003/0084996A1;2003/0084996A1; 2003/0087059A1; 2003/0087098A1; and U.S. Pat. Nos.6,875,710 and 6,942,894.

Spraying includes standard techniques for hot melt adhesive spraying,e.g., spiral, zig-zag pattern, ITW's Omega pattern, meltblown, etc. Anelastomeric film can be bonded to a nonwoven by extrusion or adhesivelamination.

In accordance with certain aspects of the invention, various materialscan be used to provide a stretchable outer cover (e.g., 22). Whenconstructing the stretchable outer cover (e.g., 22), various desirablefeatures include the following:

-   -   Mechanical properties (as expressed in terms as measured in a        Hysteresis test) during multiple medium-strain stretch-recovery        cycles, as well as the ability to survive high-strain-rate        medium depth of engagement mechanical activation in both machine        direction and cross direction without pinhole);    -   Durability (low Fuzz, high ultimate strength);    -   Visuals (white color, high opacity, cotton-ribbon-like texture,        printable, gloss);    -   Liquid barrier properties in some embodiments (absence of        pinholes or any other signs that could signal the possibility of        outer cover (e.g., 22) leakage); and    -   Low cost.

Variations in specific targets may be found depending upon whether thedesign is for a pant or a taped absorbent article (e.g., 20). Forinstance, as is described in more detail below, one embodiment of ataped absorbent article (e.g., 20) design has an integrated anchoringsystem built into the stretchable outer cover (e.g., 22) which iscreated by differential activation (an area of the stretchable outercover (e.g., 22) is intentionally left un-activated). Therefore, thedevelopment of the outer cover (e.g., 22) material takes into accountperformance targets for both pre- and post-activation states. The pantdesign may have more stringent upper limits for the CD stretch load ofthe stretchable outer cover (e.g., 22) in order to maintain easyabsorbent article (e.g., 20) application.

The stretchable outer cover (e.g., 22) may have mechanical and/orelastic properties as described herein, as well as the ability tosurvive high-strain-rate mechanical activation (i.e., incrementalstretching) in both the longitudinal and lateral directions withoutpinhole formation. Laminates that exhibit reduced pinholes fromactivation are described in U.S. patent application Ser. No. 11/361,918.Additionally, the outer covers (e.g., 22) of the present invention mayhave a low tendency to fuzz, have high opacity, and may be printable viaprinting processes common to the art.

In some embodiments of the present invention, the stretchable outercover (e.g., 22) comprises only an elastic nonwoven. In theseembodiments the total basis weight of the outer cover (e.g., 22) may beless than about 50 gsm, less than about 40 gsm, or less than about 35gsm. The outer cover (e.g., 22) material may comprise a spunbond fabricand be produced under conditions that promote optimal bond strength inorder to provide sufficient strength and durability to the outer cover(e.g., 22). Elastic nonwoven outer covers 22 may include at least oneelastomeric material in a sufficient amount to provide a minimaldesirable amount of recovery. Examples of suitable spunbond nonwovensare described in U.S. Pat. Nos. 5,470,639 and 5,997,989.

In some embodiments of the present invention, the elastic nonwovencomprises elastic/plastic bicomponent fibers, examples of which aredescribed in U.S. Pat. No. 6,225,243 and PCT App. No. WO 2006/017674, toprovide the outer cover (e.g., 22) material with better hand/feelproperties and improved spinnability. The outer cover (e.g., 22)material may also comprise webs, as disclosed in PCT App. No. WO2005/065680, formed of mixed elastic fibers (e.g., thermoplasticpolyurethane elastomer) and plastic (e.g., polyolefins such aspolypropylene) fibers, said nonwovens having good elastic recovery andtactile properties after being subjected to mechanical activation, suchas Vistamax™ available from Exxon. Another suitable elastic component isvery low crystallinity elastomeric polypropylene. Other suitableexamples of spunbond elastic nonwovens are disclosed in PCT App. Nos. WO2005/052052 and WO 2005/097031. In embodiments where the elasticnonwoven outer cover (e.g., 22) comprises mixtures or composites of bothelastic and plastic materials, the ratio of the elastic to plasticcomponents can be tailored to provide a desirable balance of bothstretch/recovery characteristics and strength/toughness requirements.High toughness is desirable to maximize the ability of the web tosurvive mechanical activation in both the longitudinal and lateraldirections.

Other exemplary materials suitable for the outer cover (e.g., 22) aredisclosed in U.S. Pat. Nos. 6,896,843, 6,225,243, 5,997,989, 5,952,252,5,695,849, 5,470,639, 5,405,682, 6,811,871, 6,103,647, 5,635,290 and5,540,976; U.S. Pat. App. Pub. Nos. 2004/0132374, 2004/0110442; and2003/0162458; and PCT App. Nos. WO 2005/052052; WO 2004/065680 and WO2006/017674.

In some embodiments of the present invention, the stretchable outercover (e,g., 22) may comprise a laminate of elastic nonwovens, such asthose described above, and an extensible film. In this embodiment, athin extensible polyolefin film layer is laminated onto the elasticnonwoven described above. Although higher basis weights are contemplatedin certain embodiments, the basis weight of the film may be no more thanabout 22 gsm, no more than about 20 gsm, and no more than about 18 gsmin order to minimize the cost of the laminate. The film may be combinedwith the elastomeric nonwoven via adhesive lamination, extrusionlamination, or any other suitable means of combining webs as known inthe art. The film may be extensible in both longitudinal and lateraldirections and able to survive a mechanical activation (i.e.,incremental stretching) process without pinhole formation over a widerange of activation strains. The film may be breathable, as discussedpreviously, whether the breathability originates from activation-inducedmicro-porosity or virtually invisible pinholes. The film may be eitherextensible, i.e., plastic, or it may be plastoelastic and exhibitpartial recovery, hence participating in the elastic recovery process.Examples of “plastic” films include films comprising standard filledpolyethylene resins, e.g., those disclosed in PCT App. No. WO2006/017518. Examples of the use of plastoelastic film formulations aredisclosed in PCT App. No. WO 2005/097031. The presence of the filmlaminated onto the stretch NW contributes to the creation of highlydesirable visuals, such as high opacity and high texture without theneed for incorporating the type of melt-blown layer described above.Alternatively, the film may comprise high-performance elastomers such asKraton-based elastomers. Further examples of elastic nonwoven/extensiblefilm laminates suitable for the present invention are disclosed in PCTApp. No. WO 2005/017518; U.S. Pub. No. 2005/0124952; and U.S. Pat. No.6,811,865, 6,623,837 and 6,096,668.

In some embodiments, the film can be the component that exhibits atleast partial recovery upon stretching. The nonwoven may be anextensible spunbond or a necked/gathered spunbond. The basis weight ofthe film may be no more than about 22 gsm, no more than about than 20gsm, or no more than about 18 gsm in order to minimize the cost of thelaminate, as well as minimize the force required to stretch thebiaxially stretchable outer cover (BSOC) up to 50% strain. The film maybe combined with the nonwoven either via adhesive lamination or viaextrusion lamination. An example of a filled elastic polyethylene blendfilm is disclosed in U.S. Pat. No. 6,909,028. Elastomericpolypropylene-based compositions are disclosed in PCT App. Nos. WO2005/052052 and WO 2005/097031. Blends of elastomeric polypropyleneswith either styrenic block copolymers, semicrystalline polyolefins orsub-micron inorganic particles can be used to enhance the stress-strainand hysteresis properties of the laminate. For example, decreasing theforce required to extend the BSOC and improving elastic recovery isachievable by adding styrenic block copolymers into a Vistamaxx polymer.Micro-porous breathable elastic films based on calcium carbonate-filledelastomeric polypropylene-based compositions are also contemplated. Thefilm may additionally increase the opacity of the BSOC and potentiallyeliminate or reduce the need for the presence of a meltblown layer inthe nonwoven.

Exemplary stretchable outer cover (e.g., 22) materials related to theseembodiments are disclosed in U.S. Pat. Nos. 6,909,028; 6,680,265;6,680,265; 6,015,764; 5,947,94; 6,627,564; 6,479,154; 6,465,073;6,313,372; 6,001,460; and 6,849,324; and PCT App. Nos. WO 2004/060669and WO 2004/060652.

In some embodiments of the present invention, an elastomer may beprinted onto a nonwoven, film, or laminate, including those describedabove, to form a BSOC. The elastomer may be printed as a film or in apattern. If printed as a pattern, the pattern may be relativelyhomogeneous over the area of the outer cover (e.g., 22), e.g., in anet-like or dot pattern, or may comprise regions of relatively higher orlower basis weight where the elastomeric component has been applied ontoat least one region of an extensible fibrous substrate to providestretch properties to a targeted region of the substrate (i.e., afterselective incremental stretching). The elastomer may be transferred ontothe fibrous substrate through a process such as gravure printing whichprovides a great deal of flexibility relative to the amount of elastomerdeposited, as well as the type of patterns that can be achieved. Detailson these embodiments, and further examples of suitable materials andpatterns, are disclosed in U.S. Pub. No. 2005/0214461 and PCT App. Nos.WO 2005/097358 and WO 2005/097512, Polyolefin blends andpolyolefins/styrenic block copolymers, such as those disclosed above,may be tailored to possess the desired rheological characteristics foradequate deposition via gravure printing. Other exemplary materials andprocesses are disclosed in U.S. Pub. No. 2005/0106980 and U.S. Pat. Nos.6,579,274, 6,503,236 and 6,264,641.

Regardless of the composition of the stretchable outer cover (e.g., 22),it can be mechanically activated in both the longitudinal and lateraldirections via any of the processes described herein. Said activationmay he used to increase the strain range over which the web exhibitsstretch/recovery properties, impart the desirable tactile/aestheticproperties to the material (e.g., a cotton-like texture), and in someembodiments, may be used to create the higher modulus components of theanchoring system, including linkages or anchoring bands. Mechanicalactivation may be achieved via ring-rolling, SELFing, and other means ofincrementally stretching webs as known in the art. In some embodimentsit may be desirable to over-bond the outer cover (e.g., 22) to furtherincrease the mechanical strength of the outer cover (e.g., 22).

As described in greater detail herein, the outer covers (e.g., 22) ofthe present invention may additionally comprise graphics 10 printed onthe outside or inside surface of one of the outer cover or waist/legband components or printed on an underlying component of the absorbentarticle (e,g., 20). The graphics 10 may be decorative, educational,entertaining, or instructional. The graphics 10 may be most clear orlegible when the printed substrate is in a relaxed condition, whileothers are most clear/legible when the printed substrate is in anextended condition. In certain embodiments, the graphics 10 compriseactive graphics, i.e., graphics which change based on environmentalconditions such as elapsed time, humidity, temperature, wetness, etc.Active graphics may be topically related to each other so as to portrayand event or action (e.g., a fish appears or disappears from acharacter's fishing line).

Tests/Methods Hysteresis Test for Elastomers/Elastomeric Composites

A commercial tensile tester from Instron Engineering Corp., Canton,Mass. or SINTECH-MTS Systems Corporation, Eden Prairie, Minn. (or acomparable tensile tester) is used for this test. The instrument isinterfaced with a computer for controlling the test speed and other testparameters, and for collecting, calculating and reporting the data. Thehysteresis is measured under typical laboratory conditions roomtemperature of about 20° C. and relative humidity of about 50%).

A sample of material is made by cutting the material to be tested 1″wide by 3″ long. The procedure for determining hysteresis involves thefollowing steps:

-   1. Choose the appropriate jaws and load cell for the test; the jaws    are wide enough to fit the sample, typically 1″ wide jaws are used;    the load cell is chosen so that the tensile response from the sample    tested will he between 25% and 75% of the capacity of the load cells    or the load range used, typically a 50 lb load cell is used;-   2. Calibrate the tester according to the manufacturer's    instructions;-   3. Set the gauge length at 25 mm;-   4. Place the sample in the flat surface of the jaws such that the    longitudinal axis of the sample is substantially parallel to the    gauge length direction;-   5. The hysteresis test involves the following steps:    -   a) pull the sample to 50% strain at a cross head speed of 10        in./min (254 mm/min)—first cycle loading    -   b) hold at that strain for 30 seconds and return to 0% strain at        the same crosshead speed—first cycle unloading    -   c) allow the sample to remain at this strain for 1 minute; and    -   d) pull to 50% strain at a constant rate of 10″/min (254        mm/min)—second cycle load    -   e) hold at that strain for 30 seconds and return to 0% strain at        the same crosshead speed—second cycle unloading        From the data collected in step 5, the following two        measurements are used:    -   a) first cycle force at 15% strain    -   b) % set, which is defined as the strain at 0.05N in the second        loading cycle. The 0.05N force is deemed sufficient to remove        the slack but low enough to impart, at most, insubstantial        stretch to the sample.-   6. Record data for first cycle load at 15% strain-   7. Record data for % set.

Method for Generating Seam Noticeability Test Images

Disposable absorbent articles to be tested for seam noticeability areconverted into digital stimuli (test images) by the following process.If the disposable absorbent article is manufactured in a closed form(e.g., a pant-type diaper), it is re-opened such that a seam resultingfrom a right front side zone (i.e., looking at the front garment-facingsurface of the article, as it is correctly worn) connected to a centralzone (i.e., the seam of interest) and surrounding area remain intact andundisrupted. The article is to be opened by cutting or opening a seamthat connects the front side panel to a back side panel. The closed formdisposable absorbent article is opened on both sides in the same manner,such that the article can be laid substantially fiat. The article istaped with double sided clear tape (such as 3M ½ inch double sided tape)to a rectangular sheet of ¼ inch thick black polyacrylate (such asLexan) larger in both lateral and longitudinal dimensions than thearticle's largest lateral or longitudinal dimension. The article iscentered on the polyacrylate sheet, and a front waist of the article,including front portions of side stretch regions, is aligned with a tapeline parallel to a waist edge. The article is pressed onto the tape linesuch that any pre-contraction in a waistband is removed, and the sidestretch regions are unstretched, but lie flat on the polyacrylate sheet.The article is then pulled along a longitudinal axis until anypre-contraction is removed. A back waist of the article, including backportions of the side stretch regions, is aligned and pressed on to asecond tape line parallel to a back waist edge. The article is tapedwith a body-facing surface against the polyacrylate sheet so that acompleted assembly presents a substantially unwrinkled and flatgarment-facing surface on a black background. Pantone uncoated solidchips 420U, 421U, 422U, 423U, 424U, 425U, 426U, and Pantone coatedprocess chips Yellow C, Magenta C, Cyan C, and Black C are affixed tothe polyacrylate sheet with tape such that the Pantone chips nor thetape touch the article, and the tape does not cover color regions of thePantone chips. The polyacrylate sheet is then scanned into AdobePhotoshop CS3 (or equivalent image editing software) at 200 dots perinch (dpi) using an HP ScanJet 3500c or equivalent scanner of sufficientsize to fit the entire polyacrylate sheet on a scanning surface.

The scanned image is converted from a raw 8 bit RGB image into an 8 bitCMYK image using Photoshop's built in converter. A new layer is createdin the scanned image, and rectangles are drawn and filled with each ofthe scanned Pantone colors (420U, 421U, 422U, 424U, 425U, 426U, YellowC, Magenta C, Cyan C, and Black C) from Photoshop's color library. Thecolor curves of the scanned layer are adjusted until a 101 pixel by 101pixel color sample taken with the color sampler tool in the center ofthe scanned Pantone chip exactly matches the color value from thePhotoshop generated color swatch. The swatch layer is then deleted.

The image is then rotated so that the waist edge nearest the seam ofinterest is at a top of a Photoshop canvas and is aligned parallel to ahorizontal axis of the canvas. A rectangular area is selectedapproximately ½ a lateral width of the article and ¼ a longitudinallength of the article and containing the entire seam of interestsubstantially centered in the area. This area is copied into a new 200dpi CMYK image with a 50% grey background and same dimensions as theselected area. The polyacrylate sheet and any other part of the newimage which is not part of the article is selected and deleted, leavingthe selected area of the article on a 50% grey background. The resultingimage is saved as a Photoshop PSD file using the embedded U.S. Webcoated (SWOP v2).

The Photoshop files resulting from this process are sent to a thirdparty digital proof printer (such as Precision Rubber Plate Company,Indianapolis, Ind.). The digital proof printer opens the CMYK Photoshopfiles using the embedded US. Web Coated (SWOP v2). The files are savedas Photoshop EPS files, keeping the embedded profile intact. The EPSfiles are placed into an Adobe Illustrator CS2 (or equivalent software)layout file measuring 24 inches wide by 20 inches high. Up to six EPSfiles are placed into each layout file, centering each EPS file in itsown 8 inch by 10 inch rectangle such that no rectangles overlap. The EPSfiles are then scaled up or down without changing the aspect ratio suchthat either the horizontal or vertical edges are ¼ inch from the 8 inchby 10 inch rectangle, and no part of the image is closer than ¼ inch toan inner edge of the rectangle. Black identifying numbers are added tothe bottom of each EPS file inside the file's rectangle, but outside ofthe image area. The resulting layout files are printed as PostScriptLevel 3 files using a Dupont Digital Proofer (or equivalent) as thePostScript Printer Description (PPD). Color Management in illustrator isset as follows: Document Profile is set to US. Web Coated (SWOP) v2,Color Handling is set to Let Illustrator determine colors, PrinterProfile is set to U.S. Web Coated (SWOP) v2, and Rendering Intent is setto Relative Colormetric (equivalent methods for creating color-matchedproof prints from digital images are acceptable). PostScript files areripped using Dupont Digital Proofer software with Precision Rubber PlateCompany's matchprint_(—)091505mdn setting for color matching (orequivalent(s)). Proofs are printed on Cromalin proofer using DupontDigital Cromalin Matte Paper (or equivalent(s)).

Control images are created from basic patterns in Adobe Illustrator CS2(or equivalent software). Referring to FIGS. 22A-D, four classes ofpatterns are used for this test: horizontal stripes 26000, zig-zags26001, repeating clusters of circles 26002, and repeating bears 26003.All patterns are created on a background CMYK color of 67:22:0:0 andwith a foreground color of Pantone 2736 C covering a CMYK document of300 mm×600 mm. Four other pattern variables are included: scale,vertical spacing, horizontal spacing, and foreground/backgroundcontrast.

Scale is defined as the size of a foreground repeating unit 26008. Forhorizontal stripes 26000, scale is twice the vertical width a of astripe 26004. For zigzags 26001, scale is the vertical distance b from adownward-pointing peak 26005 of the pattern to an upward-pointing peak26006 of the pattern, and also is twice the vertical width of a linesegment f For clusters of circles 26002 and bears 260003 scale is anedge length of the smallest size square 26007 than can be circumscribedaround the repeating unit 26008.

Vertical spacing is defined as the distance c of background spacebetween the lowest edge of one horizontal pattern row 26004 and thehighest edge of the next lower horizontal pattern row 26004.

Horizontal spacing is defined as the distance of background spacebetween the horizontal neighbors of the pattern. This variable isundefined for stripes 26006. For zig-zags 26001, this variable is thedistance d of horizontal span between an upward-pointing peak of thepattern and the neighboring downward-pointing peak of the pattern. Forcircle clusters 26002 and bears 26003, horizontal spacing is thedistance e between the rightmost edge of the repeating unit 26006 andthe leftmost edge of the right-hand neighbor. For circle clusters 26002and bears 26003, horizontal rows 26004 of repeating units 26008 whichare vertical neighbors are horizontally offset from each other by onehalf of the horizontal spacing.

Contrast is defined as the opacity of the foreground elements 26009 ofthe pattern (e.g., 26000, 26001, 26002, and 26003), with lower opacitiesresulting in lower contrast between the foreground elements 26009 andthe background 26010 of the pattern.

To convert the patterns into the final files, they are opened in AdobePhotoshop CS3 and rendered at 200 dpi resolution. An 8 inch by 10 inchsample of a 27 gsm highly extensible carded (HEC) nonwoven from BBA(Material #2003-1711-02) is placed on an 8 inch by 14 inch sheet ofblack polyacrylate alongside Pantone uncoated solid chips 420U, 421U,422U, 423U, 424U, 425U, and 426U and Pantone coated process chips YellowC, Magenta C, Cyan C, and Black C. The assembly is scanned intoPhotoshop on an HP ScanJet 3500c (or equivalent) at 200 dpi resolution.The scanned image is converted from a raw 8 bit RGB image into an 8 bitCMYK image using Photoshop's built in converter. A new layer is createdin the scanned image, and rectangles are drawn and filled with each ofthe scanned Pantone colors (420U, 421U, 422U, 424U, 425U, 426U, YellowC, Magenta C, Cyan C, and Black C) from Photoshop's color library. Thecolor curves of the scanned layer are adjusted until a 101 pixel by 101pixel color sample taken with the color sampler tool in the center ofthe scanned Pantone chip exactly matches the color value from thePhotoshop generated color swatch.

An article outline from a size 4 unseamed disposable pant is used todraw a 2D master die shape to scale in Adobe illustrator CS2. The upperright hand corner of the master die shape Illustrator page correspondsto the front waist where the side panel is on the right hand side of theouter cover. The master die shape Illustrator page is saved as anIllustrator AI file, is imported into Adobe Photoshop CS3 at 200 dpi,and is placed in its own layer of the scanned image. The die shape isfilled with the background color from the pattern file (CMYK.68:22:0:0). The scanned image layer is then placed over the die shapelayer and combined with a standard multiply at 25%. The layers areoriented such that the machine direction of the nonwoven fibers isperpendicular to a waist edge of the master die shape, the Pantone chipsare outside the die lines, and an upper right hand corner of the dieshape layer and an upper right hand corner of the scanned nonwoven layerare aligned (coincident). The scanned layer is then duplicated andcombined with a standard screen at 100%.

The seam between the right front side zone and the central zone isdefined by duplicating the screen layer and deleting all of it except a20 pixel wide stripe aligned with the master die line representing theseam between the right front side zone and the central zone. This arearepresents the seam of interest.

The right front side zone further comprises an additional layercomprised of 5 rectangular solid black stripes running perpendicular(longitudinally) to the front waist edge, measuring 26 pixels wide, andtrimmed to exactly span the longitudinal length of the right front sidezone. The stripes are evenly spaced in a direction parallel (laterally)to the front waist edge to exactly span the lateral width of the rightfront side zone. The layer is filtered with a Smart Motion Blur (angle 0degrees, distance 12 pixels) and combined with a standard multiply at20%.

The pattern image is then adjusted to account for two seam variables:vertical offset of the side seam and horizontal overlap of the seam. Themaster die shape is overlayed on the pattern image, and the central zoneis selected in the master die layer. The die layer is then turned off,and the selected area in the pattern layer is copied into a central zonepattern layer. The original pattern layer is then shifted vertically andhorizontally to simulate offset and overlap. The master die layer isturned back on, and the right front side zone is selected. The masterdie layer is turned back off, and the selected area in the pattern layeris copied into a right front side zone pattern layer.

The resulting central zone pattern layer and right front side zonepattern layer are copied into a new CMYK image with a 50% greybackground. The size of the new image is defined as a rectangular areaapproximately ½ the width of the article in a direction parallel(laterally) to the front waist edge and ¼ the length of the articlerunning perpendicular (longitudinally) to the front waist edge. Theupper right hand corner of the central zone pattern layer and the upperright hand corner of the right front side zone pattern layer are aligned(coincident) with the upper right hand corner of the new image. Thescanned image, which is also cropped to the master die shape asdescribed above, is then copied into the image with the 50% greybackground and placed over the pattern layers. The scanned image layer'supper right hand corner is aligned with the upper right hand corner ofthe 50% grey background image. The resulting control image Photoshopfile is sent to a digital proofer for printing as above.

The variable combinations used to create the control images are listedin Table 1 below.

TABLE 1 Hori- Hori- Control Vertical zontal Vertical zontal Image #Pattern Scale Spacing Spacing Offset Offset Contrast 1 bears 10 10 10 157 60 2 bears 20 10 20 7 15 100 3 bears 10 2 2 0 0 60 4 bears 30 2 10 0 0100 5 bears 30 10 2 7 0 100 6 circles 10 20 20 0 0 100 7 circles 20 20 27 7 60 8 circles 10 2 2 16 0 25 9 circles 30 2 20 16 7 60 10 circles 3020 10 0 16 60 11 stripes 10 10 2 15 16 100 12 stripes 30 2 20 0 7 25 13stripes 10 20 20 7 16 60 14 stripes 20 2 20 7 0 25 15 stripes 20 10 10 07 100 16 zig-zag 10 2 10 7 0 60 17 zig-zag 30 10 10 16 0 25 18 zig-zag20 20 20 16 15 60 19 zig-zag 30 2 20 7 15 60 20 zig-zag 30 10 20 7 7 100

Each digital proof image from both the control image set and the testimage set is cut out along its 8 inch by 10 inch rectangle and placed inan optically clear sheet protector, such as an Avery Heavyweight DiamondClear Presentation Sheet Protector. Images are randomized beforepresenting to consumers for grading in the grading room. Randomizationis achieved by listing the image identifier for all images includingtest images and control images in one column in Microsoft Excel, and arandom number in the adjacent column (formula “=rand( )”). The twocolumns are then selected and sorted in ascending order according to therandom number. This is repeated a number of times equal to the number ofpanelists, making sure to recalculate the random number column inbetween sorts, and the unique randomly ordered image identifier list isrecorded for each panelist.

While this method is drawn to the right front side zone connected to acentral zone as the seam of interest, one of ordinary skill in the artmay make adjustments to measure and evaluate other seams of interest.For example, this method is readily able, with only minor adjustments,to measure a seam formed by the front side panel in the right side zoneand the back side panel in the right side zone.

Method for Generating a Seam Noticeability Rating

Seam noticeability grading is performed by representative or perspectiveconsumers of the disposable absorbent article of interest in astandardized grading room. Consumers are selected based on being themother and primary care-giver of a child currently wearing a disposableabsorbent article of similar form to the article of interest (e.g.,pant-type diaper, tape-type diaper, etc.). The wearer of the article iswithin the appropriate target age range for the article (e,g, from 18 to36 months of age for a typical pant diaper wearer in the US) and theconsumer possesses normal visual acuity and perception as can bedetermined by the consumer possessing a valid and unrestricted USdrivers license or by receiving a passing grade on the visual andperceptual portions of the US drivers license exam. Consumers requiringprescription corrective lenses to pass the exam will be admittedprovided that they wear said lenses at the time of the seamnoticeability grading.

Referring to FIG. 21, the standardized grading room 25000 is rectangularhaving a width a of 14 feet by length b of 22 feet, the ceiling 25001 isa height of 8 feet above the floor 25002, and the room 25000 is lit bysix rectangular inset lighting fixtures 25003 a-f which measure widthsh, h′, h″, h′″, h″″, and h′″″ of 2 feet and lengths i, i′, i″, i′″, i″″,and i′″″ of 4 feet. Each fixture 25003 has three fluorescent bulbs 25009(such as Octron 4100K Ecologic Hg 32W fluorescent bulbs, available fromSylvania, Danvers, Mass.). The lighting fixtures 25003 are arranged sothat each has a shorter dimension which follows a long axis 25016 of theroom 25000. Fixture 25003 a is positioned a distance) of 4 feet fromwall 25011 c and a distance k of 3 feet from wall 25011 b. Fixture 25003b is positioned a distance j of 4 feet from wall 25011 c and a distancek′ of 4 feet from wall 25011 d. Fixture 25003 c is positioned a distancej′ of 4 feet from fixture 25003 a and a distance k″ of 3 feet from wall25011 b. Fixture 25003 d is positioned a distance j′ of 4 feet fromfixture 25003 b and a distance k′″ of 3 feet from wall 25011 d. Fixture25003 e is positioned a distance j″ of 4 feet from fixture 25003 c, adistance k″″ of 3 feet from wail 25011 b, and a distance j′″ of 4 feetfrom wall 25011 a. Fixture 25003 f is positioned a distance j″ of 4 feetfrom fixture 25003 d, a distance k′″″ of 3 feet from wall 25011 d, and adistance j′″ of 4 feet from wall 25011 a. Each fixture 25003 is fittedwith a four inch deep reflector grid 25010 which divides each fixture25003 into 18 sections measuring 8 inches by 8 inches as shown in FIG.21. The walls 25011 a-d and doors 25012 a-b are made of a material suchthat external light does not enter the room 25000 when the doors 25012a-b are closed. One wall 25011 b of the room 25000 is fitted with fourone-way mirror panels 25013 a-d arranged such that the consumer in thegrading room 25000 cannot see into the adjacent observation room (notshown). Each of the mirrors 25013 measure widths d, d′, d″, and d′″ of55 inches wide by 47 inches high (not shown) with the first mirror 25013a placed a distance c of 21 inches from the wall 25011 a and each placeddistances e, e′, and e″ of 3 inches of framing between each mirror panel25013. A bottom edge (not, shown) of the mirror 25013 is 33 inches fromthe floor 25002. There are four tables having top surfaces 25014 a-d,each having a table surface length of 60 inches by a width of 30 inchesand a height of 30 inches (not shown) from floor 25002, and arranged toform a table surface length f of 120 inch by a width g of 60 inchsurface centered in the room with the long axis 25015 of the tablesurfaces 25014 aligned with the long axis 25016 of the room 25000. Thetable surfaces 25014 (as well as the legs, etc. (not shown)) are aneutral color, as well as the two chairs (such as “Drive” Work Chairs inneutral upholstery, available from Steelcase, Grand Rapids, Mich. (notshown)). The table surfaces 25014 are covered with clean and unmarredsheets of flip chart paper (such as Expo Flip Chart 27″×34″ paper (notshown)) in a single layer with ¼ inch overlap between adjacent sheets,such that the grading surface in the non-overlapping regions has anL*a*b* color as measured by a handheld spectrophotometer (such as aSpectroEye available from X-Rite Inc, Grand Rapids, Mich.) In a randomsampling pattern where L* values lie between 82 and 92, a* values liebetween 1.5 and 2.5, and b* values lie between −6 and −4. Further, thesheets have no areas of visibly different color to a person of normalcolor vision that are not included in the measurement sampling. Thesheets are affixed to the table with ½″ masking tape around theperimeter of the grading surface, but no masking tape is used betweensheets, such that the grading surface is of uniform and uninterruptedcolor (with the exception of the ¼″ overlap areas). The floor 25002 iscarpeted with neutral colors, such that the L*a*b* color of all colorsin the carpet have L* values that lie between 25 and 48, a* values thatlie between −10 and 5, and b* values that lie between −5 and 12, asmeasured by a handheld spectrophotometer. The walls 25011 are paintedwith a non-reflective and low gloss paint with an L*a*b* color asmeasured by a handheld spectrophotometer such that the L* values liebetween 85 and 92, the a* values lie between −2 and 0, and the b* valueslie between 3 and 5. The ceiling 25001 is constructed of standard whitedrop ceiling panels.

On the table surfaces 25014, printed on sheets of standard 8.5 inch by11 inch white paper (such as Main Street Copy Paper, 84 Bright, 20pound) are the numbers 0 through 10 printed in 96 point bold Arialtypeface, centered horizontally and vertically with one number per sheetin a landscape orientation (not shown). The sheets are lined up side byside with the shorter side of each sheet aligned with the shorter sideof its neighbor(s) in increasing numerical order left to right, with therow of sheets centered horizontally and vertically on top of the flipchart sheets covering the table surfaces 25014 along the longer axis ofthe table. The sheets overlap each other by 3 inches, and no numbers arecovered by neighboring sheets. All numbers are to be visible and uprightto a viewer facing the one way mirrors 25013 and looking down at thetable surfaces 25014. The row of papers are taped to the flip chartpaper along its two longest edges with a single strip of ½ inch maskingtape on each edge.

The ambient lighting in the room is measured with a light meter (such asa Flashmate L-308S available from Sekonic USA, Elmsford, N.Y.) placedflat on the table surface with the lumisphere facing the ceiling. Themeasurement mode is set to ambient EV, and measurements are taken ateach intersection of an imaginary 6 inch by 6 inch grid across thegrading surface. The lighting configuration is replaced or adjusted ifthe illuminance at any point is outside the range of 750 Lux to 910 Lux.

The stimuli for the seam noticeability grading consists of up to 10 testimages, and a standard set of 20 control images.

Test images are pre-stacked in the assigned order prior to the consumerarriving for the seam noticeability grading. Upon arriving in thestandardized grading room, consumers are shown an actual physicalarticle comprising the seam of interest which is also represented in thetest images. For example, a Size 4 Pampers Easy-Up could be used as thereal article. Consumers are told that they will be grading images on a 0to 10 scale for how noticeable the seam of interest is, and are shownthe seam of interest on the real article. Consumers are then shown thefirst image in their assigned randomization, and shown the comparableparts between the image and the real article. The test administratorconfirms that the consumer understands the task before proceeding. Theconsumer is instructed to sort and rate the images in the stack on the 0to 10 scale where 0 is a seam that is not noticeable at all, and 10 is aseam that is extremely noticeable. Consumers are told to place theimages under the number on the scale representing that image's rating,and that they can place as many or as few images under each number asthey like. Consumers are encouraged to look through the stack of images,spread them out, adjust their ratings as they see new images, or proceedhowever they are most comfortable, letting the test administrator knowwhen they are satisfied with the ratings. During the grading, the testadministrator removes him or her self from the direct line of site ofthe consumer, and makes no comments, noises, gestures, nor otherwiseindicates agreement, disagreement, or other knowledge of the gradingorder or process. When the consumer indicates completion, she is thenthanked and dismissed, and the rating value for each of the images isrecorded.

The “Seam Noticeability Rating” is the average rating taken over allconsumers for a given image.

EXAMPLES Example 1 (FIG. 19)

The disposable absorbent article in FIG. 19 has a front region; a backregion and a crotch region between the front region and the back region.The chassis includes a liquid pervious topsheet, a nonwoven outer coveror backsheet, a liquid impervious film associated with the topsheet, andan absorbent core disposed between the topsheet and the film.

The disposable absorbent article includes a pair of extensible front earpanels each extending laterally outward from the corresponding sides ofthe chassis in the front region, and a pair of extensible back earpanels each extending laterally outward from the corresponding sides ofthe chassis in the back region. The absorbent article includes seamseach joining the front and back ear panels along the corresponding edgelines to form the two leg openings and the waist opening. The pairs ofthe ear panels are elastically extensible in the lateral direction. Theear panels are formed as unitary elements of the absorbent article andare secured to the nonwoven outer cover.

The absorbent article includes seam panels each extending laterallyoutward from each of the ear panels; and tear open tabs each extendinglaterally outward from the seam panel. The seam panels are an extensionof the corresponding ear panels. The tear open tabs are also anextension of the corresponding seam panel. The corresponding edgeportions of the ear panels are seamed directly in an overlapping mannerto make an overlapped seam structure.

A continuous belt is formed by the ear panels, and a part of the chassisabout the waist opening. The elasticized waist bands are provided inboth the front region and the back region.

The nonwoven outer cover extends across the entire transverse directionof the article, overlapping both the ear panels and the absorbent core.The nonwoven outer cover creates a continuous surface on the outside ofthe article. The nonwoven outer cover contains graphics across a portionof the visible surface of the absorbent article. The graphics overlapboth the ear panels and the absorbent core to create the appearance of amore holistic and garment-like article.

The absorbent article has graphics located on the visible surface of thetopsheet. The topsheet graphics will only be visible when the article isnot in use. The topsheet is partially suspended above the absorbent corein the crotch region to facilitate the contact between the wetness linerand the wearer in use. The graphics elements on the visible surface ofthe topsheet are actually located on the wetness liner directly belowand in contact with the topsheet.

The topsheet has the body-facing surface of the absorbent article whichis positioned adjacent to the wearer's body during use. The nonwovenouter cover has the outer-facing surface of the absorbent article whichis positioned away from the wearer's body. The absorbent articleincludes the chassis including the liquid pervious topsheet, the liquidimpervious film associated with the topsheet, a nonwoven outer cover,and the absorbent core positioned between the topsheet and theimpervious film. A wetness liner is positioned directly below thetopsheet but is narrower in width. Elastic members in the topsheetprovide the motive force to lift the topsheet and wetness liner awayfrom the absorbent core in use. The absorbent article includes the frontand back ear panels extending laterally outward from the chassis, theelasticized leg cuffs, and the elasticized waistbands. The topsheet andthe backsheet have length and width dimensions larger than those of theabsorbent core. The topsheet and the nonwoven outer cover extend beyondthe edges of the absorbent core to thereby form the side edges and thewaist edges of the absorbent article.

Each of the front ear panels is formed by a lamination of an extendedpart of the barrier flap, an elastic member and the nonwoven outercover. The absorbent article has an asymmetric, modifiedhourglass-shaped absorbent core having ears in the front and back waistregions. The chassis includes an acquisition/distribution core ofchemically stiffened fibers positioned over the absorbent core, therebyforming a dual core system.

The absorbent article includes an elasticized waistband that extendslongitudinally outwardly from the waist edge of the absorbent articletoward the waist edge of the absorbent core. The absorbent article hastwo elasticized waistbands, one positioned in the back region and onepositioned in the front region. The waistbands contain materials thathave been “prestrained.”

The elastic member joined to both of the nonwoven webs and in the earpanels while in a substantially untensioned (zero strain) condition toallow the elastic member 70 to be elastically extensible in the lateraldirection. After the elastic member is joined to at least one of thenonwoven webs, a portion of the resultant composite stretch laminate isthen subjected to mechanical stretching sufficient to permanentlyelongate the non-elastic components which are the nonwoven webs. Thecomposite stretch laminate is then allowed to return to itssubstantially untensioned condition.

Example 2 (FIG. 20)

Examples 2-4 are identical to Example 1, except that the nonwoven outercover contains different graphics on the outer cover of the absorbentarticle.

Example 3

Fifty images for seam noticeability evaluation are shown to consumersaccording to the above Method for Generating a Seam Noticeability Rating(FIGS. 23-26, for example) are black and white representations of fourimages). The four classes of patterns for this example are: horizontalstripes, zig-zags, repeating clusters of circles, and repeating bears.The range for scale is 10 mm to 30 mm. The range for longitudinalspacing is 2 mm to 20 mm. The range for lateral spacing is 2 mm to 20mm. And, the range for opacity is 25% to 100%. Further, stretch isdefined as lateral scaling of the pattern in a right front side zone.The range for stretch is 0% to 50%.

The variable combinations of the example are determined by entering theseven variables (pattern, longitudinal spacing, lateral spacing, scale,contrast, longitudinal seam offset, lateral seam overlap, and stretch)as factors in a custom design DOE in JMP v 6.0.3 (available from SASInstitute, Inc, Cary, N.C.). The software (JMF) creates the test matrixof variables and the corresponding values to investigate the designvariables' impact on the noticeability of the seam. Pattern is enteredas a 4-value categorical factor, all other variables are entered ascontinuous factors with the corresponding range values above. Anadditional 2-value categorical factor is added to represent consumergroup—two balanced groups of consumers grade separate sets of images toreduce the total number of stimuli any single consumer has to grade,thus avoiding respondent fatigue. 2^(nd) order interactions are addedfor all variables except consumer group with an Estimability value of ifpossible. The number of runs is set to 50, and the resulting designassigns 25 variable combinations to each consumer group. A random set of5 variable combinations including at least one combination for each ofthe patterns from the set assigned to the first consumer group is alsoadded to the second consumer group. A random set of 5 variablecombinations including at least one combination for each of the patternsfrom the original set assigned to the second consumer group is alsoadded to the first consumer group. Thus, each consumer from group onesees a set of 30 images including 10 images that consumers from grouptwo see, and each consumer from group two sees a set of 30 imagesincluding 10 images that consumers from group one see. 20 consumers perconsumer group are used for this test. The random variable combinationsthat are crossed between groups are selected by randomly sorting thevariable combinations assigned to each consumer group a single timeaccording to the above method for randomly sorting image identifiers,and then selecting the first 5 combinations in the list satisfying thecriteria of including at least one combination for each pattern.

These variable combinations are tested according to the Method forGenerating a Seam Noticeability Rating. The list of the design ofexperiments conditions and the results of the grading method are shownin Table 2. The randomization pattern for one group of consumers isshown in Table 3.

TABLE 2 Vertical Horizontal Vertical Horizontal Avg Image # PatternScale Spacing Spacing Offset Overlap Contrast Stretch Rating 1 bears 1010 10 15 7 60 0 5.15 2 bears 20 2 2 7 15 25 0 4.5 3 bears 20 10 20 7 15100 0 6.8 4 bears 20 20 20 15 7 100 25 6.4 5 bears 30 10 20 0 7 25 254.4 6 bears 30 20 2 0 7 60 50 6.35 7 bears 10 2 2 0 0 60 50 3.6 8 bears10 2 10 15 7 100 25 4.35 9 bears 10 10 10 7 15 60 50 5.95 10 bears 20 2010 15 15 25 50 4.725 11 bears 20 20 20 0 0 25 25 4.95 12 bears 30 2 10 00 100 0 3.15 13 bears 30 10 2 7 0 100 25 7.35 14 circles 10 2 20 0 15100 0 6.1 15 circles 10 10 20 0 15 25 25 4.9 16 circles 10 20 20 0 0 10050 4.45 17 circles 20 2 10 7 0 100 25 5.95 18 circles 20 2 10 7 7 60 506.15 19 circles 20 20 2 7 7 60 25 6.2 20 circles 30 10 2 15 0 60 0 5.921 circles 10 2 2 15 0 25 0 5.2 22 circles 10 10 10 7 7 25 50 5.45 23circles 20 10 2 0 15 25 50 5.6 24 circles 30 2 20 15 7 60 25 7.95 25circles 30 20 10 0 15 60 0 7.25 26 circles 30 20 10 15 15 100 50 6.6 27stripes 10 10 2 15 15 100 25 5.7 28 stripes 10 10 20 15 0 60 50 6.65 29stripes 20 20 10 15 0 25 25 6.4 30 stripes 30 2 10 0 15 60 50 4.45 31stripes 30 2 20 0 7 25 0 4.2 32 stripes 30 20 20 7 0 100 50 6.15 33stripes 10 20 2 7 7 100 0 6.725 34 stripes 10 20 20 7 15 60 0 7.4 35stripes 20 2 20 7 0 25 50 5.95 36 stripes 20 10 2 0 7 60 25 4.2 37stripes 20 10 10 0 7 100 0 3.85 38 stripes 30 2 2 15 15 25 25 5.75 39zig-zag 10 2 10 7 0 60 25 2.5 40 zig-zag 10 20 10 0 15 25 25 4.1 41zig-zag 20 2 4 0 7 100 50 3.325 42 zig-zag 20 10 4 15 15 100 50 4.2 43zig-zag 30 10 10 15 0 25 0 3.15 44 zig-zag 30 20 4 7 7 25 0 3.35 45zig-zag 10 2 20 15 7 25 50 5.3 46 zig-zag 10 20 4 0 0 100 25 3.625 47zig-zag 20 10 20 0 0 60 0 4.75 48 zig-zag 20 20 20 15 15 60 0 7.35 49zig-zag 30 2 20 7 15 60 25 6.95 50 zig-zag 30 10 20 7 7 100 50 5.35

TABLE 3 Panelist # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 4114 30 19 9 42 31 5 16 29 31 10 29 28 29 5 18 44 5 43 42 10 32 3 44 20 l41 28 39 5 32 6 33 43 15 15 5 29 15 33 5 44 41 28 3 20 40 5 31 29 19 5 641 33 28 42 18 42 46 33 16 20 5 28 44 10 42 18 43 16 10 9 5 1 44 27 1529 16 3 46 44 40 27 33 31 31 1 39 46 32 29 17 21 17 18 27 4 40 20 28 2721 14 6 17 27 20 18 29 44 4 15 41 31 41 30 31 31 6 21 18 18 33 10 42 404 15 15 18 19 31 40 40 6 46 39 30 1 3 4 2 41 42 46 2 17 2 6 19 40 32 4310 43 44 1 1 27 14 40 30 21 29 32 32 30 4 2 14 18 46 17 2 17 3 30 32 1817 28 19 17 9 6 10 10 41 40 31 5 21 44 21 31 17 21 5 42 19 5 43 44 18 2721 2 20 41 33 1 1 14 20 10 6 10 18 28 10 9 39 6 4 30 44 40 28 18 3 41 22 43 39 31 33 17 17 33 2 46 19 39 16 17 19 16 14 17 30 28 10 32 32 4 228 39 5 6 6 40 5 43 3 9 1 3 40 3 27 4 1 1 40 3 19 4 18 15 33 31 30 39 3044 30 5 41 39 14 42 5 3 32 27 3 44 41 33 17 15 32 4 18 16 17 28 39 46 3316 14 33 1 40 4 15 29 29 42 39 40 44 41 43 10 31 2 43 3 28 30 28 42 1714 21 4 39 1 1 46 33 4 27 9 33 28 20 39 9 46 2 21 28 29 31 9 42 4 29 2115 6 14 14 21 20 2 40 30 6 14 28 44 6 29 39 17 31 4 28 19 1 33 6 1 16 324 29 19 9 2 46 2 30 20 1 14 2 19 3 33 46 27 42 30 14 18 18 29 20 9 18 1041 42 14 16 16 17 21 43 32 46 30 27 17 42 6 39 30 20 6 20 9 6 31 20 4614 20 39 3 32 17 9 31 6 3 33 46 39 5 9 43 15 10 41 30 2 28 14 42 3 44 444 19 20 3 29 33 32 21 40 27 32 27 18 3 1 29 5 44 20 43 15 20 46 9 15 1441 44 32 43 30 10 32 27 14 20 41 19 27 42 27 16 31 27 21 10 20 43 46 146 32 43 16 29 15 6 21 43 15 21 30 27 16 4 16 19 39 19 2 16 29 10 15 246 15 40 4 1 10 9 39 4 16 19 16 15 2 40 21 3 5 43 9 19 28 42 9 21 42 4419 42 40 41 14 27 16 31 43 15 9 41 18 9 21 33 39 46 16 10 32 41 19 43 9

After the seam noticeability grading test, the consumers are asked atwhat point on the 0 to 10 scale the noticeability of the seam negativelyimpacts their perception of the quality of the article. The averageresponse in this example is 6.28.

All documents cited in the Detailed Description of the Invention are, inrelevant part, incorporated herein by reference; the citation of anydocument is not to be construed as an admission that it is prior artwith respect to the present invention. To the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

1. A method of constructing a pull-on disposable absorbent articlehaving a first waist region, a second waist region, and a crotch regiondisposed therebetween, the method comprising: attaching the first sidepanel to the first waist region such that a first seam is formed;attaching the second side panel to the first waist region such that asecond seam is formed; attaching the third side panel to the secondwaist region such that a third seam is formed; attaching the fourth sidepanel to the second waist region such that a fourth seam is formed;attaching the first side panel to the third side panel such that a fifthseam is formed and a first leg opening is formed; attaching the secondside panel to the fourth side panel such that a sixth seam is formed anda second leg opening and a waist opening is formed and such that thedisposable absorbent article is in a pull-on configuration; printing afirst graphic object on a viewable outer surface of the first sidepanel; printing a second graphic object on a viewable outer surface ofthe second side panel; printing a third graphic object on a viewableouter surface of the third side panel; printing a fourth graphic objecton a viewable outer surface of the fourth side panel; printing a fifthgraphic object on a viewable outer surface of the backsheet; registeringat least one of the first, second, third, fourth, and fifth graphicobjects relative to one or more positions of another feature ofabsorbent article selected from the group consisting of a portion of anabsorbent core, a portion of the waist region, a portion of a topsheet,a portion of the backsheet, a portion of the first, second, third, orfourth ear panel, a portion of a waist feature, and a registration mark;and registering at least one other component of the first, second,third, fourth, and fifth graphic objects relative to one or morepositions of another feature of absorbent article selected from thegroup consisting of a portion of an absorbent core, a portion of thewaist region, a portion of a topsheet, a portion of the backsheet, aportion of the first, second, third, or fourth ear panel, a portion of awaist feature, and a registration mark.